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Dev. Cell (Mechanical) Railway Board Rev.

1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(RAILWAY BOARD )
*****

Draft Functional Requirement Specifications (FRS) for


GLOBAL TENDER No: 2015/DEV.CELL/ICCI/1
March 2017

For Supply, Installation, Commissioning and Operation of


On Board Condition Monitoring Systems for
Indian Railway Rolling Stock
to
Specification Number: OBCMS/DCM/N/1, November 2016

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

Foreword:
1. This document consists of two parts:
Part-I
Reasoned document for demanding the specific Functional Technical Requirements
from the bidders.

Part-II
Functional Technical Requirements (FTR) to which the equipment and services
shall be procured.

2. The comments, if any, on these Functional Requirement Specifications (FRS) may


be emailed to Director Mechanical Engineering (Development)/Railway Board
upto mid night of 15.05.2017 at binay.jha@gov.in.

3. It is requested that comments may kindly be sent to Director Mechanical Engg.


(Development)/Railway Board within the stipulated time. The responses received
after above mentioned time shall not be entertained.

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

Part-I

Reasoned document for demanding


the specific Functional Technical Requirements
from the bidders.

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

Preamble:
1. In order to maintain transparency in Indian Railways need to demand certain functionality
from the On-Board Condition Monitoring System while maintaining certain high level of
baseline standards, this reasoned document is being put up for information of all concerned.
The technology benchmarks to be followed in acquiring these systems have been laid down so
as to guard against obsolesce. Indian Railways has, while deciding the technology, made sure
that only the technology is being defined. No specific product which may fall under patent
protection of a specific company has been chosen to be endorsed by Indian Railways since
that would construe that such a specification would become biased by naming the product
thereby defeating the very purpose of framing open and fair specifications.
2. These reasoned comments are based on the responses received from the various respondents
to the EOI and the discussions of the offers received with the concerned authorities/officials.
3. For examining the responses received against the Expression of Interest (EoI) for purchasing
the On-Board Condition Monitoring System, experts/officers were nominated at both Railway
Board and at RDSO. Academic Expert too has been involved in examining the current
practices, technology progression and available technologies to safeguard the interests of
Indian Railways. This was duly approved by MRS (the then MM).
4. Further, in order to give a fair chance to all respondents, they were offered a chance to
showcase their systems in presence of a number of senior officers at the Railway Board in
Live mode via internet. This was held in February, 2016.
5. For the purpose of brevity, the following acronyms have been used:
WSN Wireless Sensor Node
DC Data Concentrator
EoI Expression of Interest
IR Indian Railways
RDSO Research Designs and Standards Organization
6. As per the EoI, the On Board Condition Monitoring System for monitoring of vibrations and
later to be extended to additional functional parameters which will be specified after the first
phase is rolled out use the following major components:
6.1 Wireless Sensor Node (WSN).
6.2 Power source for the WSN.
6.3 Data Concentrator (DC) for collecting and pre-processing data being collected by various
WSN.
6.4 Communication system between WSN and Data Concentrators (DC).
6.5 Communication system between Data Concentrators and Central processing ground
stations.
6.6 Algorithms that analyse raw data to create actionable alerts.

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

Various vendors who responded to the EoI have given different solutions to achieve the
objectives and the demands made by Indian Railways.
7. All the respondent firms were also invited to demonstrate their working systems. The live
demonstration of various systems by each firm was done as per the following schedule:-
S. No. Name of the Firm (M/s) Date of Presentation
1 SKF India Ltd
23-02-2016 & 19-04-2016
2 Medha Servo Drives Pvt. Ltd
3 Apna Tech. & Solutions Pvt. Ltd 23-02-2016
4 Amsted Rail Company Inc./ IONX 23-02-2016 (Through Webinar)
5 RSL Electronics Ltd 23-02-2016
6 Secure Rail India Pvt. Ltd 23-02-2016
7 Structural Solutions Pvt. Ltd 23-02-2016
8 IRD Mechanalysis Ltd 23-02-2016
9 RT Vision Technologies (p) Ltd 23-02-2016
10 Stone India Ltd 26-02-2016 (Tele-conference)
11 GE India Industrial Pvt. Ltd. 10-03-2016
12 Star Navigation Systems Group Ltd 13-04-2016

M/s ECM, Italy presented their system in AM(PU)s chamber via video conferencing on
13-04-2016.
M/s Amsted, USA presented their system on a later date via video conferencing on 23-02-
2016
M/s Star Navigation Systems presented their system in AM(PU)s chamber on 13-04-
2016.
Each firms personnel gave their presentation to a group of senior Railway Officials.
8. The objective of the live presentation exercise was to see if the vendors who showed
interest in the EoI and submitted their responses have the necessary product as well as the
technology running in any commercial railway system in the world to offer to Indian
Railways. The aim, in short, was to see that Indian Railways should not be treated as an
experimental lab or Guinea Pig by any firm to develop such technology and product.
9. Therefore, very fair opportunity was given to every respondent to present their product
and to showcase the capabilities and limitations of their system.
10. The On-Board Condition Monitoring Systems for monitoring of vibrations has been envisaged
to use same vibration sensor to be used for dual purpose to monitor the health of the rolling
stock/bearing and to monitor the state of track over which the vehicle is passing. The system
uses the following major components:-

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

10.1 Wireless Sensor Node (WSN) that serve to provide signal for bearing as well as track
health analysis from the same node.
10.2 Power source for the sensor nodes.
10.3 Data Concentrator (DC) for collecting and pre-processing data being collected by various
WSN.
10.4 Communication system between WSN and Data Concentrators (DC)
10.5 Communication system between Data Concentrators and Central Processing ground
stations.
10.6 Algorithms that analyze raw data to create actionable alerts.

11. Various vendors who responded to the EOI have given different solutions to achieve these
objectives. While the standards and practices for communicating data between the sensors and
data concentrators and between Data Concentrators and Ground control are fairly standard and
established by industry norms, the major variation in the firms proposals was with respect to
providing power to the Wireless Sensor Nodes and their ability to monitor the state of health
of both track as well as bearings using the same WSN. Fitment methodology was another
factor on which the firms had variety of solutions some intrusive and some non-
intrusive solutions.

12. While it is clear that all companies have capabilities to analyse data using their algorithms, it
is clear that algorithms require continuous fine tuning and this can be done effectively only
when the Sensor system is being used on a regular basis and real-time data is being processed.
This is only possible if the system is being used by major users and actual user conditions are
being used to fine tune the algorithms. Very evident example of algorithms acquiring highest
levels of sophistications is GOOGLE SEARCH ENGINES. Comparisons between search
results in first year of launch of Google Search and today would be completely different since
based on usage and the clients demands, the search programs were improved and made faster
and more efficient and accurate. This demonstrative of how algorithms require continuous and
extensive usage for improvements.

13. Attached is a chart that shows the summary of response of all respondents. Based on the
responses, the following key points emerge: -

13.1 Besides the fact that a well tested and extensively used software algorithm is certainly
likely to give more accurate and user-friendly results, the Power Source for WSN is
clearly another qualitative differentiator. The following alternatives have been suggested
as a Power Source by various firms:-
- Batteries
- Bearing/Axle rotation being used to generate power.
- Energy Harvester
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Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

- Using the power from on-board source of the vehicle to power the Sensor Node.

14. A summary of the merits and de-merits of the various options of powering the sensor
nodes is given below:
Types of
Pros Cons
Power Source
Harvesting Generates 1) Major alteration required in fitting on existing
from Bearing sufficient amount bearing system.
Rotation of power for 2) Invasive with regards to changes required in the
continuous bearing assembly. Each manufacturer of such energy
monitoring. source would have unique system hence no
uniformity would be achieved causing major problem
in interchangeability of bearings/ components.
3) Has moving parts inside the bearing hence there is an
added risk that if the inner parts break/fail, whole
bearings reliability becomes suspect and it becomes
prone to catastrophic failure without giving
indications.
4) Takes substantial time to install/inspect and repair
when needed.
5) There shall be connectors inside the bearing housing
which are again possible points of failure.
Harvesting Generates 1) This is still more of an R&D project with the
from axle sufficient amount company and no railroad is using their system.
rotation of power for 2) Major changes required in bearing system.
continuous 3) Invasive with regards to changes required in the
monitoring bearing. Reach manufacturer of such energy source
would have unique system hence no uniformity
would be achieved causing major problem in
interchangeability of bearings/ components.
4) Has moving parts inside the bearing hence there is an
added risk that if the inner parts break/fail, whole
bearings reliability becomes suspect and it becomes
prone to catastrophic failure without giving
indications.
5) Takes substantial time to install/inspect and repair
when needed.
6) There shall be connectors inside the bearing housing
which are again possible points of failure.
Batteries Very good 1. Battery itself has too many possible modes of failure
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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

quality batteries that too when fitted in such critical application and
appear to be low when subjected to such harsh working environment.
initial cost 2. Maintenance Costs in replacing batteries would a
solution for logistic problem.
power generation 3. Once the WSN is opened for replacing batteries,
to power the sealing it back to Factory spec of IP7 requirements
sensor. would require sanitized work area.
4. Disposal of replaced batteries would end up adding to
the e-waste.
5. Types of batteries to be used with WSN are generally
termed as VERY HAZARADOUS. Disposal of such
large volumes of these hazardous materials would be
an environmental hazard.
6. Only ONE railroad has shown confidence in battery
powered WSN systems for Condition Monitoring.
7. As battery life reaches its end, data integrity becomes
a suspect due to end-of-life voltage-current
characteristics.
8. Calculations suggest that power requirement for
efficient continuous monitoring is not possible using
non-rechargeable batteries.
9. Rechargeable batteries would require energy
harvesting mechanism that would have to produce
power greater than power required for continuous
monitoring.
Energy Clean source of 1. May be the most initially expensive solution.
Harvesting energy. 2. Volumes will bring eventual cost down and mitigate
No replacement the initial high cost but
of energy source. 3. Life cycle cost shall become much lower.
Tried and tested
technology by
major railroad.
Sufficient amount
of power
generated to
power WSN.
Maintenance free
Does not need
replacement till

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

end-of-life so all
logistic problems
of locating a
dying energy
source (such as a
dying/dead
battery) and
replacing them
are eliminated.
Wired sensors Huge amount of 1. Very invasive.
using power power available 2. Limited to passenger coaches and locomotives. It has
from On on tap. been generally seen that wired connections especially
Board DC below the under-frame are prone to breakage and
power source damage due to ballast hit/harsh environment and
vandalism.
3. Cannot be proliferated to freight wagons.

Indian Railways needs to look at the operational aspects too while implementing On-Board
Condition Monitoring System. These operational aspects are discussed below: -
14.1 Using Batteries to power WSN: Presuming that 2,50,000 wagons, 50,000 coaches and
10,000 locomotives are fitted with one battery powered sensor on each axle box, a total of
3,10,000 vehicles will be fitted with 25,00,000 sensors that have at least one battery in
each sensor. Even with the state of the art batteries on date, average battery life in such
harsh environment shall be appx. 5 years. Therefore, every year, Indian Railways will
need to keep track of all these 25,00,000 batteries at ALL TIMES. The average
replacement requirement of the batteries will be 25,00,000 5 = 5,00,000 batteries every
year in LOCATIONS ALL OVER THE COUNTRY. This is an impossible task. Further,
these spent batteries will be hazardous waste so the same will have to be disposed of in an
expensive manner ensuring that they dont cause environmental pollution. Hence as
conscious decision has been taken that using batteries to power the sensor nodes
cannot be accepted by Indian Railways.
14.2 Axle rotation/Bearing rotation powered energy generation: Axle/Bearing rotation
powered systems necessitate that the bearing, including the housing needs to be modified.
An arrangement has to be made inside the bearing housing by adding a magnetic generator
mechanism with gears, magnets, wires etc. to generate energy from rotation of the
axle/bearing race. Internal structures and components of bearing are very critical
components. All along, Indian Railways is moving in the direction of keeping axle
bearings as sealed entity with very rugged and as few components inside it as possible so

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

as to reduce the chances of failure (more the number of components inside more the
chances of one of the components failing resulting in complete failure of the bearing).
Furthermore, each bearing manufacturer will have his own design of energy generator
inside the bearing housing and such a system will be proprietary to each company since
performance issues of the bearing itself will get linked to the complete assembly. With
more components inside the bearing, the points of failure will increase thereby decreasing
the reliability of the bearing assembly as a whole. Presently, approximately 700-800
bearings are failing catastrophically on line. Since these bearings do not have any
components inside them that go not belong to the bearing manufacturer, failure analysis is
much more precise and ownership of setting right the failure is well defined. With third-
part components inside the bearing, it will be impossible to fix responsibility for a bearing
failure.
Servicing this power generating system inside the sealed axle-box will also necessitate
setting up specialized maintenance centres within all the workshops and manpower would
have to be trained to deal with the complete system as a whole. Therefore, a decision has
been taken by the competent authorities that the no powering system shall be
permitted in which the bearing needs to be opened/modified/retrofitted with power
generation sub-system. Energy generation using axle rotation/bearing rotation also
cannot be permitted since additional system to generate electrical energy only for
powering a sensor cannot be permitted as it will increase monitoring and
maintenance needs of the same.
14.3 Energy harvester based power source for powering sensors have been offered by one
company (M/s Perpetuum UK) and is being developed by two more companies (M/s SKF
and M/s IONX). These systems are self-contained within the sensor and are fit-and-
forget systems as an integral part of the sensor itself. The life of the sensor along with the
energy harvester is stated to be 20 years. Energy harvesters are not a new concept. Due to
their rugged, maintenance-free nature and due to their long life, such energy harvester
systems are being used by large number of industries including defence industry. The fact
that M/s SKF and M/s IONX are developing their solutions on energy harvester powered
systems is a testimony to the fact that whenever and wherever rugged and maintenance-
free sensor systems are needed, energy harvesters are the choice of power source. Energy
harvesters powered sensors are based on powering the sensor using energy harvested by
converting mechanical vibrations or tapping ambient conditions to generate electrical
power. There are number of methods to harvest mechanical vibrations or ambient energy
to generate electrical energy. In view of the above operational advantages, it has been
decided to agree to adopting energy harvester based technology for powering the
sensor nodes. Therefore bidders shall not be permitted to offer systems that are
powered by battery if these internal batteries do not have self-sustained charging
system using sealed energy harvester system within the same enclosure as that of the
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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

sensor/data concentrator. However, test regime to support the claim of life of such
sealed sensor nodes incorporating energy harvester must be furnished by the bidder so that
the claim can be verified by Indian Railways. The minimum life of such energy harvester
based wireless sensors shall not be less than fifteen (15) years when they are offered to
Indian Railways as a solution against the above bid.
14.4 Frequency of sampling rate of data for monitoring condition of bearings and track
for actionable analysis: There is a trade-off in designing a system of condition
monitoring of bearings, including condition monitoring of track. The choice is between
sampling at frequent closely-spaced intervals or at infrequent, widely space intervals (say
a couple of times a day only). Continuous monitoring should detect a problem straight
away but it usually very energy hungry and puts severe computational load on the
processing system on the sensor board itself. As against this, data acquisition at widely-
spaced intervals demands very little power from power source and puts very small demand
on the computation system but has a very high probability of missing out on possible
alarm-causing events. Periodic sampling at widely spaced intervals (say just a few times in
a day) is cheaper, uses less energy, and allows time for data cleaning and filtering but a
real problem will be diagnosed only during the next processing session. This may be
acceptable only in some situations that change slowly such as cracks slowly developing in
bridges. Therefore, as a trade-off it is essential to acquire data at sufficiently frequent
interval so as to get near-real-time inputs of the condition of the component being
monitored. E.g. if a train is travelling at say 110 km/h, sampling the data from sensor
at say even once every hour would result in missing out the track vibration signature
for a stretch of 110 kilometres i.e. if any portion of track in between these two
points 110 km apart happens to have a dangerous spot in between and which gave a
vibration impulse to the sensor, it would be missed by the monitoring system due to
large sampling interval.
Therefore, a decision has been taken by the competent authorities that sampling of
data shall be done by the sensor at short interval say every three (3) minutes or even
less but not longer than five minutes spacing. Faster sampling rate shall be factored
in in case other conditions of performance between two bids are found equal. Data
may be held after sampling on board the sensor and may be transmitted in bursts so
as not to miss out significant events and to preserve energy reserve on the sensor.
15. It is the intention of Indian Railways to place purchase order of such system on one
primary firm and two developmental firms provided they all meet the performance
criteria without diluting any performance demands as asked for by Indian Railways.
16. The entire system shall be of a single identical design including sensors and harvester etc
for fitment on coaches, wagons and locomotives. No request to permit dissimilar systems
for coach, wagon or locomotive should be made. The performance demands of the

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

system shall not be diluted even if the firms cite the reason that design of such systems
especially power source is difficult for fitting on freight wagons.
17. Since Indian Railways wishes that for developing such a system, it should not be made
the experimental laboratory/Guinea pig, the system offered by the bidder must be
commercially operational for at least one year in at least two railway systems.
This current document is drafted based upon the Indian Railways Functional Requirement
Specifications (FRS) and on the basis of the current technology available and keeping in view the
progression of such technology in near future. Indian Railways decision is to leapfrog in terms of
technology rather than move ahead in small incremental steps.
This is the final version of the specifications and is being uploaded for information of all
prospective respondents so that they can prepare their proposals for submission keeping in view
the stringent and technologically demanding requirements of such a system. This system, in
principle, has been showcased to Honble Prime Minister of India and other senior policymakers
during Rail Shivir on 20th Nov, 2016. This system shall be the backbone for bringing paradigm
shift in monitoring and maintenance methodology and operation of IRs rolling stock.
Notice for Bid Invitation shall be published shortly.

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Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

Part-II
Functional Technical Requirements (FTR)
to which the equipment and services shall be procured.

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Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

A. Preamble:
Indian Railways wishes to install railway vehicle mounted, On Board Rolling Stock
Condition Monitoring System that shall monitor the health and safety of key components of
the coaches, freight cars, locomotives and rail track from the point of view of component
health and its safety. Such a system would finally result in improved safety, improved
reliability, higher utilization, increased up-time and reduced operation cost of the railway
assets by enabling Predictive Maintenance and reduction in sudden catastrophic failures of
these assets.
B. Broad Functional Requirements:
The On Board Condition Monitoring System of Rolling Stock will enable Predictive
Maintenance of coaches, wagons, locomotives and track by meeting the following
functionalities:
a. Improving the reliability and safety by early warning of distress in or impending
failures in wheels and wheel bearings using the vibration signature of the sensors that
are strategically placed on the axlebox. To also do track condition monitoring using the
same sensor(s) to indicate deterioration in the health of tracks.
b. Improvement in reliability of these assets by detecting early signs of deterioration in
wheels, wheel bearings and track condition thus providing ample time for planning
preventive and predictive maintenance and avoiding sudden breakdowns in service.
c. Enabling scientific decision-making for maintenance of assets based on accurate
deterioration trending and quantified indices of state of health of these assets so as to
plan condition-based maintenance rather than time-based maintenance.
d. It should be possible to Install On Board Condition Monitoring System on Rolling
Stock on in service trains/coaches/wagons/locomotives within normal scheduled
maintenance time when the rolling stock comes for routine inspection and maintenance
usually at the end of the trip This is needed to reduce cost of installation, increased
asset availability and prevention of train service disruption while reaping benefits of
such predictive maintenance systems.
e. The proposed system should be capable of being used with existing roller bearings
without having to make any structural modifications in the roller bearings or any major
intrusive modification in the bearing/bogie frame.
f. Easy operation of the On Board Rolling Stock Condition Monitoring System by simple,
automatically generated and actionable alerts.
System should be future proof to the extent that any change in communication technology
and sensor electronics should not degrade its performance nor should necessitate that Indian
Railways is compelled to change the purchased system to reap its intended benefits.
18. Key Requirements:
18.1 The standards for compliance are as specified in Annexure1.
18.2 Vendors Qualification:

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Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

Following experience of the original system manufacturer or the Lead Technical firm
in case the bid is submitted by a JV of firms in which the technology and the systems
shall be under exclusive ownership of one single firm, shall be the minimum
acceptable experience for the respondents to qualify them for taking part in the
bidding process when request for proposal is called for:
a. Installation of at-least 5,000 wireless sensors on trains across different types of
Coaches or freight cars. These sensors must have run in the field for at least 2 (two)
years.
b. Experience of over 1,000,000,000 sensor-kilometres of accumulated service operation
of wireless (non-battery) sensor nodes.
c. Submit documentary evidence to Indian Railways showing how asset maintenance
costs have been reduced by their customers by deploying the system that they propose
to supply.
d. Names of at least two customers along with their contact details who shall supply
testimonials as asked for in (a), (b) and (c) above.
e. Proof of demonstration of successful detection of such damaged bearings which would
otherwise have failed but have been caught by their system at least three months in
advance of their failure.
f. The effectiveness of the wheel and bearing condition monitoring system shall be
already proven in passenger coaching vehicle and locomotive/powered passenger
stock. Since Indian Railways is not aware of any deployment of such systems on
freight cars due to absence of reliable power source, same WSN should be capable of
being deployed on freight vehicles without any change of configuration or change of
functional parts so as to maintain universality in deployment across all types of stocks.
Examples of successful wheel and bearing monitoring case studies wherein damage to
bearing, wheel and track was successfully demonstrated well before occurrence of
failure must be furnished with evidence of damages so detected, their documentation
and field staffs observations.
18.3 Deliverables expected from the System:
a. System shall be capable of operating effectively with 2G cellular data network
coverage. System must be scalable to upgrade to 3G and 4G as and when needed and
should choose the 2G/3G/4G networks automatically to ensure that the communication
does not fail for any reason. Automatic switching between 2G/3G/4G should be done
as a standard design of the communication system.
b. All data shall be captured and transmitted to a central server for inspection and
analysis from the data concentrator. Transmission should be secure and encrypted. IR
should be given the decryption methods and keys so that it is possible to decode and
extract this data stream at the input to the analysis software for later use by Indian
Railways for its own analysis.
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c. Events that cause critical alert situation like impending failure should be dealt with
differently. Such alerts should also be conveyed to central monitoring systems on an
urgent, escalated-priority basis overriding normal communication methodology for
flagging them for taking urgent action.
d. Vibration data shall be captured at every 3 (three) minutes or lesser. If required, it
should be held in buffer on board the WSN/Data concentrator and then transmitted to a
central database for processing, analysis and alert generation when the train is in
normal service (at speeds over 25 Km/h) and as soon as it comes into cellular data
coverage. In the event of cellular network not being available, the data shall be held
for the entire required time until cellular network coverage becomes available and then
data must be transmitted at the earliest. The data holding buffer must be designed
accordingly.
e. The condition monitoring system shall not be specific to any particular bearing type or
to any specific bearing supplier but should function with multiple types of bearings
that are running on Indian Railways.
f. Respondent must specify the accuracy of their system on overall basis with reference
to FalsePositive and FalseNegative alarm performance. Methodology of verifying
the stated accuracy including the test regime to be followed to substantiate their claim
must be specified. Indian Railways shall, while calling for technical and commercial
bids, take into consideration these details furnished by the vendors. In absence of any
numbers given by the respondents, Indian Railways shall set its own values based on
its experience of similar equipment running in the field in India. Not more than 5%
false positive shall be accepted by Indian Railways.
g. Vibration shall be measured and transmitted when train is operating in normal service
(speed greater than 25 Km/h) and shall effectively work at speed upto 200km/h.
h. The system shall be capable of measuring, analysing and transmitting an alert in the
event of detecting a high-risk occurrence pointing to an impending failure within
typically three minutes and maximum ten minutes with appropriate 2G/3G/4G data
connectivity. Time stamp and GPS location stamp of the system shall be used to report
such events. Faster response times shall be preferred.
i. The condition monitoring software algorithm should also report the state of the health
of the bearing, wheels and the track on discreet band zone Green Zone for
unconditionally safe to run, Yellow Zone - for beginning of noticeable deterioration
and Red Zone - for indication to pull out the asset as soon as possible since it is
reaching an impending failure stage.
j. The condition band (Green band, Yellow band and red band as mentioned in
i. above shall, after appropriate configuration and calibration, enable the operator to
distinguish between bearings/wheels and track with none or low level of rate of
degradation, those that require to be kept sight of for further deterioration and finally

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Stock Condition Monitoring System

those requiring prompt attention to allow continued reliable operation of the train
without a line-failure of the asset.
k. Besides the above mentioned Zone Bands, all parameters of the all assets should be
possible to be plotted and trended over time/distance to identify the deterioration
rate/trend. This should enable prioritisation of maintenance activities, thus enabling
reducing damage to track and maximising useful wheel life.
l. The wheel condition monitoring system must be able to enable the operator to detect
defects arising of Rolling contact fatigue like wheel shelling, wheel flats, etc.
m. In the event of sensor damage, a warning shall be generated to the control center to
enable safe replacement of the sensor at the next maintenance location. The control
room/system should have a mechanism to flag and display such defective sensor/data
concentrator continuously to the personnel manning such terminals until the same
is/are repaired/replaced.
n. Alert levels shall be configurable and set by the operator to enable simple, actionable
responses. However, the vendor shall take the responsibility of identifying the values
and setting the limits and alarm thresholds in consultation with Indian Railways. A
time period of two months shall be given to the supplier to understand the Indian
Railways operations and maintenance scenario and practices for setting such
thresholds. The supplier shall be obligated to assist Indian Railways personnel in
understanding the logics of the thresholds so set by him to the full satisfaction of the
Indian Railways personnel. A maximum period of six months from the date of
installation on the last vehicle of all the purchased units shall be permitted to the
supplier to do any fine-tuning of their system algorithms.
o. A system of cellular text alerts and acknowledgements to nominated maintenance
personnel of Indian Railways shall be designed with necessary checks and
compliances. Such a system should be completely automated with provisions to
escalate level of attention in case the nominated personnel do not acknowledge the
relevant text.
p. The training materials and documentation for the system shall include historical
examples of bearing, wheel and track defects that have been monitored successfully,
with a correlation between monitored degradation, action taken by operator and
parameter levels on return to normal after maintenance.
q. All sensor data shall be time, date and location stamped. Data location shall be
typically accurate to 10m or better. Date and Time stamp shall be taken from the GPS
system only.
r. The allocation of sensor nodes to a data concentrator and train will be easily
configured either through the terminal input of the data concentrator using non-contact
programming device (Bluetooth, NFC, Zigbee, etc.) or by remote connection with the
user website.

Page 17 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

s. The only configuration required for sensor nodes shall be the sensor node serial
number with railway coach/wagon/locomotive number.
t. Decryption keys shall be provided wherever necessary to use the incoming data to the
analytics program. Proprietary communication protocols or data formats/information
interchange formats used by the system when interfacing during system integration
with other sensors or while scaling up the deployment should be shared with Indian
Railways with the express permission that the same can be used by Indian Railways
for its own use without any restrictions.
u. IR should also be able to extract the data in usable format that is being sent between
WSN and data concentrator and data concentrator and analytics program.

19. EQUIPMENT AND SYSTEMS: -


For the purpose of this work, the system as asked for by Indian Railways is assumed to consist
of: -
i) Sensor(s) fitted on the axlebox/axlebox-cover with minimally intrusive fitment so as to
capture the temperature of the axle box and the vibrations generated by axle bearings and
those generated by wheel and track.
ii) Data concentrator an electronic unit that is used to collect data from the sensors and
transmit it to the control room using over the air data transmission method.
iii) Central collection and data processing centre for collection and analysis of data and for
communicating the various alarms or maintenance messages to the concerned railway
personnel on an automatic basis.
For the purpose of calculation and scoping of this document, it is assumed that for
monitoring each axle-box one sensor each shall be fitted as near to the axle box as per
firms design plan so as to capture the most accurate data required for making alert
decisions, i.e. two sensors for each wheel-set. Indian Railways Locomotive is a six-axle
vehicle and the coach and freight cars are four axle vehicles at present.
19.1 Specifications & design of critical components shall also be approved by Ministry of
Railways through its approved agency before they are fitted. Sensors and systems shall be
as per existing standards for compliance for fitment on Railways coaches, wagons and
locomotives. Notwithstanding any such approval, the respondents shall stand fully
responsible in respect of design, manufacture and serviceability of the complete system.
The respondents shall also be responsible for ensuring that the systems so fitted shall not
affect the safety of the other railway equipment.
19.2 Certain number of units of the system shall be subjected to extreme limit of stress testing
to the point of their failure so as to investigate the design margin available in the system
before failure. Such units shall not be counted towards the number of bearings supplied
but shall be part of product acceptance test by Indian Railways.

Page 18 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

19.3 Firm shall also submit the Laboratory Test regime to test the sensors and data
concentrator to evaluate the claims made by the firm towards the functionality and
life expectancy claimed out of the equipment proposed to be supplied. These tests
should also include accelerated ageing test wherever applicable wherever any
particular components life is claimed to be more than the warranty period of the
equipment.
19.4 During the currency of contract, after the basic system is proven, IR desires that certain
additional parameters should also to be monitored since the basic backbone system of data
collection, data analysis and monitoring shall already be in place. List of such additional
parameters is enclosed in Annexure-1. The respondents shall develop all interfaces
required to integrate such additional sensors into the On Board Rolling Stock Condition
Monitoring System without having to change the basic architecture of the system already
approved and installed on IRs rolling stock. The cost and transfer the know-how to IR
upon completion of the interface development shall be borne by the supplier of the main
system.
19.5 For the future, when the Bids shall be called, they shall be based on Two Packet
System Consisting of Technical Offer and Commercial Offer. Technical offer
shall be evaluated first and the commercial offer shall not be opened or given any
cognizance if the bidder fails to meet the technical requirement in their technical offer.
19.6 The indigenization plan for the On Board Rolling Stock Condition Monitoring System
System offered against this tender should be submitted along with the technical bid. Indian
Railways insists that at least 75% by cost of 25% of the supplies of the total quantity
ordered on the firm should be either made in India within two years of initial supplies.
This is to ensure that indigenization is taken seriously and completely aligned with the
MAKE IN INDIA program of the government.
19.7 Indian Railways reserve the right to cancel the tender at any stage without assigning any
reason therefor.
20. Following information must be furnished while submitting the response to this
document: -
i) Any Must-change items to keep the system running and the periodicity of changing
such must-change items.
ii) The quantum of false alarms both false positive and false negative must be declared at
Technical Bid stage itself. False positive alarms shall not exceed 5%. Non-adherence to
this shall be viewed seriously and shall result in severe financial penalty besides making
the supplier of such equipment ineligible to participate in any tender of Indian Railways
for purchasing equipment/sensor/system to monitor health of any rolling stock
component or its systems/sub-systems, for a period of ten years subsequent to detection
of such violation.
Page 19 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

iii) The respondents must specify the Up-time of their system while submitting their bids.
Any non-availability of their system, below their specified Up-time shall incur
penalty. Quantum of penalty shall be advised at the time of framing the final
specifications. Penalty shall be telescopic in nature. The minimum acceptable up-time
for the sensors and data concentrator and data capturing and analysis systems including
control room equipment shall be 98% not counting communication failure attributable to
equipment/systems that are not owned by the successful supplier(s).
21. WARRANTY:
21.1 The respondent will provide warranty at the nominated maintenance depots for 39 months
from the date of supply or 36 months from date of commissioning, whichever is earlier.
During warranty, the respondents shall rectify the defects, if any, in the On Board
Rolling Stock Condition Monitoring System system by replacing components as
necessary at his cost.
21.2 If the warranty support is not provided within 7 (seven) days of notice demanding the
same, Indian Railways shall levy appropriate penalties for non-functioning of the system.
For this purpose, even if a sub-assembly within a complete unit (one
coach/wagon/locomotive) is not working, the entire coach, wagon or locomotive system
shall be deemed to be non-functional. Rate of penalty shall be calculated and notified at
the time of calling for Request for Proposals. The rate of penalty shall be telescopic in
nature so as to discourage non-compliance for long duration.
21.3 Respondent shall also undertake to ensure availability of all requisite spare parts for a
minimum period of 15 years after purchase from the date of Letter of Acceptance of the
offer when Technical and Commercial Bids are called for. In case any specific spare part
is not available at a later date for whatever reason, an equivalent or superior spare part that
performs all the functions of the original spare part can be accepted subject to preapproval
of the same by RDSO. In making such substitution of spares, which should have minimum
impact on the existing architecture/software/layouts etc. The expenditure in modifying the
system/sub-system/architecture shall be borne by the suppliers.
21.4 The respondent shall give an undertaking that should there be any need for
modification arising out of field trials or during the currency of the contract as per the
deliverable functional capability promised by the respondent, it will be carried out by the
respondent without any cost to the Indian Railways.
22. System Configuration:
22.1 The Rolling Stock and Track Condition Monitoring System shall have the following
elements:
- Sensor module (Sensor Node).
- Communications network.
- Analysis Software.

Page 20 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

22.2 The bidders shall not be permitted to offer sensor systems that are powered by battery
alone if their internal batteries do not have self-sustained charging systems using sealed
energy harvester within the same enclosure as that of the sensor/data concentrator. The
Ingress Protection rating requirement shall apply to the complete unit. Indian Railways
shall not permit replacement of the internal battery for 15 years (minimum life of such
sealed sensors).
22.3 Bidders are required to offer sealed sensors and data concentrators with a minimum life of
15 (fifteen) years.
23. The order for purchase, installation commissioning, monitoring and generation of alerts using
the On-Board Condition Monitoring Systems shall be placed on one primary firm and two
developmental firms. There shall be no dilution in technical standards and requirements for
supplying such equipment by the developmental firms.
24. The offered monitoring systems should be similar to commercially running On-Board
Condition Monitoring Systems in at least two railway systems in the world for a continuous
period of one year.
25. The accelerated aging test for such energy harvester based sensor so developed by these firms
shall have to be submitted along with the technical bid. Indian Railways may conduct its
accelerated aging tests even at a later date after supply and if the equipment fails to qualify in
such test, the firm shall be penalized. Non-adherence to this shall be viewed seriously and
shall result in severe financial penalty besides making the supplier of such equipment
ineligible to participate in any tender of Indian Railways for purchasing
equipment/sensor/system to monitor health of any rolling stock component or its systems/sub-
systems, for a period of ten years subsequent to detection of such violation. Permission to fit
harvester based sensors and data concentrator shall be given only after necessary tests to
ascertain the claimed longevity of the sensor and data concentrator have been successfully
carried out by Indian Railway to its full satisfaction.

26. Since the On-Board Condition Monitoring Systems shall have to be fitted on the entire fleet of
Indian Railways, bids shall be called in the next phase in which IR is also exploring
possibilities of service based payment system. Firm shall have to bear the entire cost of
fitment of sensors and allied hardware, creation of back end IT systems for analysis and
monitoring, system of generation of alerts and passing on the same to designated officials of
Indian Railways. Payment to the supplier shall be made based on the basis of functioning of
the system by way of transmitting data to the control centres and correct generation of and
transmission of maintenance and other alerts. As a general guide for such a model, a period of
24 hours shall be reckoned as the unit for making payment per day. Any sensor system on
vehicle that does not transmit its data for a period of six hours within 24 hours of the day shall

Page 21 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

be deemed to be defective and payment for that vehicle shall not be made even if only one
sensor out of all the fitted ones is defective or any small defect of any nature including
damage caused by track ballast hit, etc. is there in the system. The automatic computer
generated log of the functioning of the system shall be used to determine such inoperative
vehicles. However, the final call shall be taken at a later date.

27. Sensor Node:


27.1 The wireless sensor node shall contain sensor for vibration and temperature. A single
sensor node shall be capable of monitoring condition data from the track, wheel and
bearing.
27.2 Sensor node shall be contained in a single robust housing with no external electrical
wiring or connections (for sensors powering or communication purposes). This is essential
to prevent failure of the system due to damage to such cables or connectors due to factors
like ballast hit, vandalism, etc and to ensure fail-safe operation.
27.3 The sensor node should be deployed on or close to the axle box assembly. The fitment
arrangement shall first have to be preapproved by the firm from nominated agency of
Indian Railways before commencing supplies.
27.3.1 Each sensor node shall have a unique electronic identification number, accessible from
the web/NFC/non-contact reader and should be clearly marked on the sensor at the time
of fitment.
27.3.2 Sensor node shall be sealed to IP67 standard.
27.3.3 Sensor node housing shall be suitably treated to protect against corrosion.
27.3.4 The WSN and data concentrator shall operate satisfactorily over the range of specified
in the operating environment standards mentioned elsewhere in this document.
27.3.5 In order to maintain standardization of equipment, the sensor nodes to be fitted on
Coach, freight wagon and locomotives shall be of the same design.
28. On-vehicle Communications Hub (or Data Concentrator):
The Data Concentrator shall incorporate a GSM communication system and GPS location
device.
i) The data concentrator shall have an IP 67 rating.
ii) The data transmitted from the data concentrator to the remote storage and processing
centre shall be encrypted.
iii) The SIM(s) for cellular communication should be hardwired in the data concentrator
itself.
iv) The data concentrator shall comply with all relevant standards as mentioned elsewhere in
this document.
29. Software and Algorithms:
i) The data analysis software shall analyse the received sensor data and produce simple
actionable alerts for maintenance staff.
Page 22 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

ii) The alerts and condition information must be generated automatically without the need
for operator intervention.
30. Track Monitoring System Requirements
i) The system shall be capable of monitoring the track condition not only for the level of
shock and vibration but also the change of these levels with time so as to identify the
deterioration trend.
ii) Information shall be presented from management perspective on a map making use of the
GPS coordinates of the data so captured to enable maintenance action.
iii) Time based trend shall also be available to be viewed for analysing the level and rate of
degradation.
31. Installation
i) Sensor node shall typically be installed in less than one man-hour under normal
conditions and the required special (proprietary) tooling will be supplied to all depots and
maintenance sheds/workshops of the Indian Railways.
ii) Sensor node shall be capable of being fitted to the existing in-service axle bearing
assemblies at any time in the lifecycle of the bearing.
iii) Sensor node shall be capable of being fitted to both legacy and new rolling stock without
the need for buying special bearings or special bearing housings/parts. Minor non-
structural modification that does not necessitate removal of bearing cover or opening of
bearing can only be permitted.
iv) Sensor node fitment shall not require any change to the existing bearings. The sensor
nodes fitment shall be non-intrusive i.e. no requirement to modify the bearing, bearing
housing or the bearing cap/casing.
v) Necessary anti-pilferage measures as per international norms shall be built into the
installation so as to reduce the danger of theft or vandalism. Indian Railways shall take all
necessary precautions to prevent vandalism but Indian Railways cannot be held
accountable for any vandalism etc.
vi) Configuration Diagnostics: A suitable display and log shall be provided to clearly show
the list and health of all sensor nodes attached to each data concentrator. Health check of
system shall be done once every 24 hours and log of such a check must be maintained at
the data processing centre for later scrutiny if required.
vii) The replacement of any defective WSN or data concentrator shall be possible to be done
in less than 30 minutes.
32. Communications:
i) Communications to and from the WSN and data concentrator shall be wireless.
ii) The wireless communication from the sensors shall be free from interference by
passenger communication systems such as Wi-Fi, Bluetooth and cellular radio, etc.
33. Front-end presentation at the control room:
Page 23 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

The information for monitored rail assets with sensors shall include but not be limited to:
1. Location (shown on a map and available as a downloaded data file).
2. Speed of the vehicle.
3. Direction of travel of the vehicle.
4. State of health of the monitored asset viz. bearing, wheel and track.
5. Necessary APIs (Application Program Interface) with for this, along with the mapping
software, should be developed by the supplier of the system including obtaining any
authorization for use of Geo-mapping data and software. No fees shall be paid by Indian
Railways for use of such third party resources like maps, etc.
6. The website shall be hosted on a non-proprietary cloud computing system with scalability,
and geographical resilience with adequate redundancy and with mirrored redundant
servers at each geographical location. The cloud platform for this purpose shall be a
secure and reputed one. The software shall at a later date be required to be shifted onto
India-based Cloud services of choice that shall be jointly decided between the supplier and
Indian Railways. Cost of shifting over to Cloud in India shall be borne by the supplier of
the equipment.
7. The User interface shall have to be preapproved by Indian Railways before the same is
deployed. Any changes to firms own dashboard shall have to be done by the firm at its
own cost to the satisfaction of Indian Railways. The website shall have multi-level query
menu as per the demands of Organizational hierarchy relevant to that particular
administrative level of person logging in.
34. Access to Data and Alerts:
34.1 Condition Monitoring information shall be securely accessible on computer, tablet or
smartphone from anywhere with broadband internet access.
34.2 Access to the information shall be security protected to a recognised industry standard and
shall be of hierarchical in nature depending on the administrative position/privilege of the
accessing client.
34.3 The software shall escalate the urgent alerts to successive end users in the event of
acknowledge of the alert not being confirmed by its first intended recipient.
34.4 An audit trail shall be available to monitor and record website activity as well as data
concentrator logs.

*****

Page 24 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

ANNEXURE - 1
The following standards/equivalent standards or their latest versions shall govern the
specifications to which the equipment and systems shall comply with. Whenever there is any
ambiguity regarding interpretation of standards, procedures and norms, the stricter of the
conflicting norms shall be applicable.
Following standards shall apply as appropriate to the various components, subassemblies
and subsystems/systems: -
I. AAR-S-5702 : for testing for effect of working environment conditions.
II. CMMI-SVC : for service provision
III. IEC 60571 : for railroad electronics
IV. IS 2500 : for sampling plans
V. ISO27001 : for information security management systems
VI. ISO 9001 : for Quality Management System
VII. ISO 9421 : guidelines for user interface development
VIII. NMEA 2000
(IEC61162-3) : for sharing of GPS Data
IX. TIA-942 : for server uptime
X. UL60950 : for safety of mains powered equipment.

AAR Manual of Standards & Recommended Practices, Railway Electronics, Standard S-5702.

MECHANICAL STANDARDS:
Bogie mounted equipment must conform to
BS 7608:2014 (fatigue)
EN 13749:2011
Bogie and coach mounted equipment must conform to:
EN 61373:2010 (shock and vibration tests)
EN 12663 (2010) (equipment mounted to vehicle bodies)
EN 45545 (2013) (fire precautions)

ELECTRICAL STANDARDS
EN 62311 and EN 62479 (exposure to EMI)
EN 50121 (electromagnetic compatibility)
R&TTE directive 1999/5/EC
EN 301 489
Power supply: EN 50155 and EN 50121

ENVIRONMENTAL STANDARDS:
EN 50125-1
EN 60529

Page 25 of 26
Dev. Cell (Mechanical) Railway Board Rev. 1
Draft Specifications for Development, supply, installation and commissioning of On-Board Rolling
Stock Condition Monitoring System

GENERAL:
- EN 50126 (Railway Applications - The Specification and Demonstration of Reliability,
Availability, maintainability and Safety (RAMS)).
- Equipment to be designed and manufactured under ISO 9001.
- NEMA-3 Compliant enclosure unit.
- Indian Railways Standard (IRS) General Conditions of Contract (GCC) shall prevail while
doing interpretation of the various financial, operative and purchase conditions in executing
the above-mentioned work.

*****

Page 26 of 26
Clauses Amsted Medha Apna Tech. Stone India Structural Solutions Private Ltd. IRD Mechanalysis Ltd. RSL Electronics Spec. Star Navigation SKF Secure rail RT Vision
Requirements
Rail(IONEX) Perpetuum
This current document is an Expression of Interest (EoI) published by the Government of India, Ministry of Railways to solicit and examine Complies Complies Complies Complies Complies . No comments Complies No comments Noted No comments Complies
the response of the firms/companies/entities that are supplying or capable of supplying the Goods and Services as per the details
mentioned in this document before Indian Railways finalize the specification of the equipment and services and associated conditions
before entering into a contract. The current document is therefore to explore the response from the prospective bidders.
I
m
p
o The timelines and the quantity of units mentioned in this document are subject to change and shall be firmed up while the Technical and No comments No comments No comments NO comments NO comments No comments No comments No comments Noted No comments No Comments.
r R Commercial Bids are called for by the Indian Railways at a later date.
t e Final specifications and conditions of contract shall be made after going through the response and comments of the respondents, in No comments No comments No comments NO comments NO comments No comments No comments No comments Noted No comments No Comments.
a s response to this document. Invitation for Bids shall be called for after the specifications are finalized by Ministry of Railways, Government of
n p India (Railway Board).
t o Some of the operational conditions of contract are briefly mentioned in this document. These are subject to change based on the No comments No comments No comments NO comments NO comments No comments No comments No comments Noted No comments No Comments.
n examination of response received and in line with the Indian Railways Standard condition of Contract.
N d
However, it may please be noted that the decision of Ministry of Railways, Government of India (Railway Board) shall be final while No comments No comments No comments NO comments NO comments No comments No comments No comments Noted No comments No Comments.
o e
addressing the issues raised by respondents in response to this document.
t n
i t
c s Ministry of Railways, Government of India (Railway Board), may change any or all of the terms and conditions and/or technical, commercial No comments No comments No comments NO comments NO comments No comments No comments No comments Noted No comments No Comments.
e or operating requirements in their final document from the ones, which are specified in the current Expression of Interest. The revised set
of conditions and specifications that shall then be part of final Invitation for Bids document which will be published at the time of calling for
t Bids.
o
Ministry of Railways, Government of India (Railway Board), reserves the right to summarily reject any or all of the offers received in No comments No comments No comments NO comments NO comments No comments No comments No comments No comments No comments No Comments.
response to this Expression of Interest without assigning any reason therefor.

Indian Railways solicits response from interested companies/entities who are technically capable and are reputed in the field of condition No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. YES Indian Railways solicits response from interested Indian and foreign companies/entities who are technically
monitoring of railway rolling stock to submit their Expression of Interest (EoI) for supply and operation of On Board Rolling Stock capable of Development in India or are reputed in the field of condition monitoring of railway rolling stock to submit
Condition Monitoring System on coaches, wagons and locomotives and to set up Ground support systems at Divisional Control Rooms their Expression of Interest (EoI) for supply and operation of On Board Rolling Stock Condition Monitoring
(approximately 60), at Head Quarter Control Rooms (approximately 20), at Maintenance depots of Coaches (approximately 150 depots), System on coaches, wagons and locomotives and to set up Ground support systems at Divisional Control
Wagons (approximately 140 depots) and Locomotives (approximately 50 locomotive sheds) in the field, at Railway Board (approx. 10 Rooms (approximately 60), at Head Quarter Control Rooms (approximately 20), at Maintenance depots of
installations) and at RDSO (approx. 8 installations), among other places for use by Indian Railways. These above mentioned ground Coaches (approximately 150 depots), Wagons (approximately 140 depots) and Locomotives (approximately 50
support systems shall primarily access the data after analysis on the Analytics Cloud from the on-board condition monitoring system locomotive sheds) in the field, at Railway Board (approx. 10 installations) and at RDSO (approx. 8 installations),
1 among other places for use by Indian Railways. These above mentioned ground support systems shall primarily
access the data after analysis on the Analytics Cloud from the on-board condition monitoring system, Capable of
all items connected with safely heading should change.

To facilitate the respondents in understanding of the Indian Railways operations and rolling stock, the respondents should contact Complies Complies Complies NO comments NO comments No comments Complies No comments Noted. YES No Comments.
Executive Director Mechanical Engineering (Development), Room No. 333, Railway Board, Raisina Road, New Delhi -110001,
email: edmed@rb.railnet.gov.in who will issue them authority to contact Chief Mechanical Engineer, Northern Railway for necessary
interaction with the users to understand the operation condition and maintenance methods and conditions in the field. While making this
1 .1 request to Executive Director Mechanical Engineering (Development), respondents must clearly and succinctly write down in their request
letter - their doubts, queries and issues, which they wish to resolve in their field visit.

This document has been published to show the Intent of Ministry of Railways Government of India (Indian Railways) to explore various No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. YES No Comments.
technologies available in the field On Board Rolling Stock Condition Monitoring System for coaches, wagons and locomotives before
finalizing the specifications of the equipment and systems. Technical and Commercial Bids to purchase such system shall be called after
the available technologies are explored and most appropriate technology is chosen by Indian Railways, based on the response submitted
1 .2 by the respondents in response to this document. Final specifications for on board rolling stock condition monitoring systems shall be
frozen after examining the response received in response to this EoI document.

The respondents are required to give an undertaking to express their willingness to enter into a comprehensive Annual Maintenance and No comments No comments No comments NO comments NO comments No comments No comments No comments SKF,Suggest here YES Changed to Rolling Stock as well as Railway Tracks and associated Static/ Dynamic support facilities. This is
Operation Contract (AMOC) with Indian Railways during warranty and post warranty period for operation and maintenance of On Board to have a necessary as there is close connection between defects in Rolling Stocks and Fixed assets like Railway tracks and
Rolling Stock Condition Monitoring System & Control Room Support Facilities. AMOC will be inclusive of spares and consumables discussion on the other supports. Defects identified in any part(s) in any Rolling stock, may be caused by track defects as well as
required for maintenance and operation of On Board Rolling Stock Condition Monitoring System and the ground support facilities. warranty and Environmental conditions. This should ideally look into a total picture from Safety point of views, for ALL types of
This would also include attention during periodical overhaul (POH) of the coaches/wagons/locomotives in the designated workshops AMOC contect after Rolling stocks, all types of Tracks, Terrain and effects of weather. Sensors & associated components/ sub-
However, Indian Railways reserve the right to enter into AMOC with the supplier of the On Board Rolling Stock Condition Monitoring the technical assembly should be easily replaceable. As defects can accur anywhere, anytime.
System or with any other contractor beyond the period of warranty. Comprehensive Warranty of the entire system shall be for a period of feasibility of the
3 (Three) years from the date of successful installation. product has ben
scrutinized by the
2 indian railways
depanding upon the
finalization of the
The initial period of AMOC shall be 5 (Five) years but The AMOC contract is likely to be revised upwards after it is reviewed after a period No comments No comments No comments NO comments NO comments No comments No comments No comments No Comments.
technology to be
of five years and shall be renewed in time slabs of 5 (Five) years subsequently as per operational exigencies, technological change, IRs
adopted.
experience and administrative requirement of Indian Railways.

3 OPERATION OF ON BOARD ROLLING STOCK CONDITION MONITORING SYSTEM:


The supplier shall take full responsibility of not only maintenance but also day to day operation of On Board Rolling Stock Condition No comments No comments No comments NO comments NO comments No comments No comments No comments SKF,Suggest here YES. No Comments.
Monitoring System supplied by him and its functioning at the end-user premises. It will be charged under the AMOC referred to in Para 2 to have a
above. discussion on the
warranty and
AMOC contect after
the technical
feasibility of the
product has ben
scrutinized by the
(a) indian railways
depanding upon the
finalization of the
technology to be
adopted.
To facilitate the supplier maintaining and operating the On Board Rolling Stock Condition Monitoring System systems during AMOC, No comments No comments No comments NO comments NO comments No comments No comments No comments SKF,Suggest here The AMOC is not feasible looking at type of system which shall be installed on trains moving across all length and
if awarded to him, the railways shall provide without charge to the supplier a suitable place with general working amenities like electricity to have a breadth of India. 1. The System should be Maintenance less or Maintenance free system, as much as
etc. at a convenient/suitable place in the coach maintenance depot/workshop/ Control Offices for maintenance of the system. discussion on the possible. Considering any parts or any subsystem can fail at critical run time in Hostile, Unhabitated and terrible
warranty and inclement weather conditions. 2. The System should be modular enabling guard/ driver/ TXR to replace it if an
AMOC contect after alarm is generated. An AMOC cannot work becauseno manufacturer canhave such a large force all over India to
the technical repair in each and every train.
feasibility of the
product has ben
scrutinized by the
(b) indian railways
depanding upon the
finalization of the
technology to be
adopted.

4 DELIVERY OF EQUIPMENT AND SYSTEMS:-


For the purpose of this work, the systems as asked for by Indian Railways is assumed to consist of: - Complies(detailes Complies(detaile NO comments NO comments No comments No comments
i) Sensor(s) fitted on the axle ends Complies(detailes Complies(detaile Complies NO comments Complies . No comments Complies No comments Complied NO, Sensors will not be 1. Sensors placement on axle and its replacement for defects calls for high expertise trained persons. This will also
available in s available in fitted on the axle ends. not be timely and/or cost effective. 2. The Main purpose is to detect defects in bearings, wheels, track geometry
Schedule of Clause Wise Sensor(s) will be fitted in 3D, suspension and other parameters, these can be easily analyzed by Vibrations (Frequency Domain Multi-
Technical Compliance to 'close to the bearing Layer Analysis) by placement of miniature MEMS sensors, in a small box, placed at any convenient place. 3.
Requirement ) Schedule of housing 'but not Sensors must not only sense 3-Axis Acceleration but also 3-Axis Tilts (Gyros) in real time without fail. 4. Sensor
Technical necessary on the axle placement in a convenient place in compartments and wagons, may apparently indicate some loss of Important
Requirement ends. Frequency data loss or attenuation.This apprehension may come from fact that Bogie or wagon suspension
(i) Appendix-9) system may be the cause. This may not be true mostly as suspension systems response in frequency domain is
only visible in very low frequency area. May be much less than 1 Hz. Furthermore, Sensor placement at axle will
not be able to monitor much about wagon itself being unstable or defective, unstable or defective, unbalanced or
even in serious condition of total fatal.

ii) Data concentrator an electronic unit that is used to collect data from the sensors and transmit it to the control room. The Sensors or the Complies(detailes Complies(detaile Complies NO comments NO comments No comments Complies No comments SKF Smart sensor NO." intelligence" Wiil 1. Data Concentrator or local train control servers role can never be limited to indicate component failures. 2.
data concentrator shall have n-built intelligenceto raise alarms on the vehicle itself in case the signals generated by the sensors indicate available in s available in includes smart in be off the train(in the Local Servers (Train control units) in locomotives for example, should interact with such sensors without fail,
impending failure of the component. Schedule of Clause Wise build intelligence Cloud).Caculation wiil always. Else stand by server (For example Guard Bogie must take over , during such server failures. 3. Real time
Technical Compliance to that can talk directly be done in the cloud Hot standby is always considered for Mission Critical Systems, so far. Let us start thinking a moving train is also
Requirement ) Schedule of to cloud.SKF Smart and can then be one such item. This is more so as such servers, now a day's cost very less. 4. Local Servers must act as fully
Technical sensor does not relayed to driver via the Autonomous Control system. It should, to the extent possible, detect defects either in Wagon/ Bogies, Tracks,
Requirement need any Electronic cellular network. Environment as well as personnel connected with actual operations. It becomes semi-autonomous control system
Appendix-9) Media like Data when it gets reliable and secure additional support from cloud. Smart/ Itelligent train itself cloud communication fail
concentrator.The to many times for moving train system.
(ii) benefits are less
electronic
component ,less
cost ,compact
system ,easy to
programme,easy to
diagnose and less
maintenance work.

For the purpose of calculation and scoping of this document, it is assumed that eachaxle-boxshall be fitted with one sensor each, i.e. Complies(detailes Complies(detaile Complies NO comments NO comments No comments Complies No comments Noted
two sensors on each wheel- set. Indian Railways Locomotive is asix-axlevehicle and the coach and freight cars are four axle available in s available in
vehicles at present. Schedule of Clause Wise
Technical Compliance to
Requirement ) Schedule of
Technical
Requirement
Appendix-9)

Within 2 (two) months of placement of the order, drawings and specifications indicating functional and technical details of the system shall No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. YES No Comments.
be submitted by the firm to Railway Board for approval. The fitment drawings shall clearly indicate not only the dimensions and details Indian railway has
critical to fitment of On Board Rolling Stock Condition Monitoring System in individual type of coaches/wagons/locomotives but also to provide drawing
those critical to proper functioning of the system. Specifications & design of critical components shall also be approved by RDSO before /CAD of the bearing
they are fitted. Sensors and systems shall be as per existing standards for compliance for fitment on Railways coaches, wagons and housing design to
4.1 locomotives. Notwithstanding any such approval, the respondents shall stand fully responsible in respect of design, manufacture and verify the sensor
serviceability of the complete system. fitments.

Within 2 (two) months of the approval of the drawings and layouts, the supplier shall offer at least five On Board Rolling Stock No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. YES 1. Clearly this new system must be considered as a pilot trial and more time should be given since it is very unlikely
Condition Monitoring System systems for prototype inspection to Indian Railways at firms premises as per Development Cells that a proven system exist for a foolproof reliable ( Total safety, not only bearings) solution suitable for Indian
Schedule of Technical Requirements as enclosed. The arrangements for necessary facilities like test stand etc. will be done by the supplier conditions. 2. Uncertainly in specifications, features and limitations, algoriths trials acceptance criteria etc. need to
4.2 at his works at his cost. Two units of the system, other than these five, shall be subjected to extreme limit of stress testing to the point of its EVOLVE during trials.
failure so as to investigate the margin available in the system before failure.

Within 1 (one) month of prototype approval by Indian Railways, 140 numbers of "On Board Rolling Stock Condition Monitoring No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. YES,We assume this No Comments.
Systems" shall be supplied to nominated coach maintenance/production units, locomotive sheds and Freight Maintenance deport on means 140WSNs and
Indian Railways as per its nomination for installation & commissioning trials for fitment clearance. Respondents must make sure that their 1DC
equipment does not require any modification at this stage to undertake necessary dimensional modifications to this On Board Rolling
4.3 Stock Condition Monitoring Systems. Respondents are encouraged to inspect and get familiar with the Indian Railways Coaches,
wagons and locomotives before submitting their proposals.

After successful fitment & commissioning of On Board Rolling Stock Condition Monitoring System Systems on the No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. YES 1. Indian Railway must try parallel at least 3 new types of systems from 3 different Vendors/ organisations/
coaches/locomotives/wagons as mentioned in para 4.3 above, the supplier will be given a clearance by Indian Railways for fitment as per Companies. 2. This type of plan is a very closely guarded secret from major Japanese and Korean companies.
the contract. The firm shall make supplies of 6800 units in the first phase to IRwithin 2 (two) months of fitment clearance. This is done when one is not sure about the best solutions in a untried, untested, complex and vast like Indian
railway system. (Even for a seemingly very less complex MP3 Decoder assembly coding project, Toshiba, in year
2000, engaged two Indian companies with same task and same time frame (6 months) and same cost (US$ 60 K)
4.4 3. Since budget could be a limitation, available amounts can be partitioned suitably amongst the participants,
based on trial units. 4. 25% to 50% quantity should be reserved for Indian Companies desiring to Develop this
system in India and should be given extra time to develop and implement.
Once the proving trials with 6800 units of the above is completed for a duration of six months to the satisfaction of Indian No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. YES No Comments.
Railways as per stipulations and technical requirements spelt out in the Draft Schedule of Technical Requirement, the remaining
quantity of equipment (for fitment on Approximately 10,000 locomotives, 50,000 coaches and 2,25,000 freight wagons) shall be
supplied and fitted by the supplier at a rate not less than that specified by Indian Railways and at locations as per mutual
agreement due to exigencies of the operations. Fitment shall be done on Locomotives and passenger coaches in the first phase
4.5 of the deployment. The proving trials shall be deemed to have been concluded on the date on which the joint report of the
performance of the system is accepted and jointly signed by the firm supplying and operating the systems and Indian Railways.

After the proving trials are completed in para 4.5 above, permission shall be granted to the firm for supplying, installing and operating the No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. YES No Comments.
remaining systems of Onboard Condition Monitoring Systems. These systems shall be proliferated further and by the end of three months
of the conclusion of the proving trials mentioned in para 4.5, they shall be fitted on Passenger coach trains at a minimum rate of 45
rakes per month and the same system shall be fitted on Locomotives at a minimum rate of 200 locomotives per month. Rate of
fitment on Freight trains shall be notified after the successful demonstration of the system on the freight trains after the supplies are made
4.6 as per Para 4.4 above, due to the rough operating conditions to which freight wagons are subjected. However the pace of fitment of this
system on freight train rakes shall not be less than 50 rakes per month.

The respondents shall develop all interfaces required of the On Board Rolling Stock Condition Monitoring System to monitor the list Complies(detailes Complies(detaile Complies NO comments NO comments No comments No comments No comments Noted. YES No Comments.
of parameter on the coach, wagon and locomotive sub-assemblies and structures, as enclosed at Annexure-1, at their cost and transfer available in s available in
the know-how to IR upon completion of the interface development. Schedule of Clause Wise
Technical Compliance to
Requirement ) Schedule of
4.7 Technical
Requirement
Appendix-9)

5 SPECIAL NOTES:-
For the future, when specifications are finalized based on response to this document, the Bids shall be invited on Two Packet System No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
Consisting of Technical Offer and Commercial Offer. The two offers shall be enclosed and sealed in individual envelopes
superscribed Technical Bid for On Board Rolling Stock Condition Monitoring System and Commercial Bid for On Board Rolling
Stock Condition Monitoring System respectively.
5.1

These two envelopes then should be placed in the third envelope and should be sealed and superscribed Technical and Commercial No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
Bid offer for On Board Rolling Stock Condition Monitoring System

The respondents are hereby advised to study the existing coach, wagon and locomotive design thoroughly and also the Indian Railways No comments No comments No comments NO comments NO comments No comments No comments No comments SKF,Suggest here NO Comments No Comments.
track structure including its layout in their own interest before submitting their proposal. to have a
discussion on the
warranty and
AMOC contect after
the technical
feasibility of the
product has ben
scrutinized by the
5.2 indian railways
depanding upon the
finalization of the
technology to be
adopted.

The indigenization plan for the On Board Rolling Stock Condition Monitoring System System offered against this tender should be No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments 1. Indian Railway must insist this point in harder terms. This also will be in accordance with PM's "Make in India"
submitted along with the technical bid. Indian Railways would insist on indigenizing at least 30% of the cost of each unit by the end of three Plan. Any Vendor/ Group/Companies not agreeing to local Manufacturing within 1 years from Trial completion may
years from the date of first supply after obtaining the first set of equipment as stated in para 4.5. Out of the remaining equipment, 60% be barred from trials itself. 2. 25% to 50% quantity should be reserved for Indian Companies desiring to Develop
indigenization of cost shall be completed by the end of five years from the date of deployment as per para 4.5. Suppliers/respondents who this system in India and should be given extra time to develop and implement.
5.3 can indigenize the production of entire 100% of the equipment in India may kindly indicate so giving their plan of action including the
timelines. Indigenization shall be done by the firm who is awarded the contract.

All electrical/ Electronic equipment used in the system shall be tropicalized for use under environmental conditions as indicated in the No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
5.4
RDSOs Schedule of Technical Requirements.
When Request for Proposals are called for, the bids including technical details should be submitted in triplicate and each of the bids should No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
5.5
be complete in all respects.
When Request for Proposals are called for, Bidders shall then be required to deposit Bid guarantee as per Indian Railways condition of No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
5.6
contract when the Bids are invited. Any bid not accompanied by bid guarantee shall be summarily rejected
The respondents should submit their comments and compliance to the specifications in all respects and not in abstract or cryptic manner. If Complies(detailes Complies(detaile No comments NO comments NO comments No comments No comments No comments Noted. NO Comments Complies
there are any deviations to the specifications, a deviation statement indicating the clause/sub-clause, deviation proposed and justification available in s available in
thereof should be enclosed. Schedule of Clause Wise
Technical Compliance to
Requirement ) Schedule of
5.7 Technical
Requirement
Appendix-9)

Bids against the Request for Proposals, when called for, will be entertained only from those firms who have purchased the bid documents No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
in their own name or by their authorized representatives on payment of the specified charges. The firms should enclose the proof of the
5.8 same along with their bid document when submitting their offer. Detailed procedure shall be spelled out at the time of calling for Bids at a
later date.

BIDS FROM RESPONDENTS, WHO HAVE NOT PURCHASED THE BID DOCUMENTS THEMSELVES, BIDS NOT ACCOMPANIED BY No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
BID GUARANTEE AND BIDS FROM AGENTS WITHOUT LETTER OF AUTHORITY FROM THE MANUFACTURERS ARE LIABLE TO BE
5.9 SUMMARILY REJECTEDBID. TELEX, FAX AND OTHER INCOMPLETE BIDS ARE LIABLE TO BE SUMMARILY REJECTED.

Indian Railways reserve the right to cancel the Expression of Interest or the tender at any stage without assigning any reason. No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
5.10

When Notice inviting tender is published and bids are called, the respondents must clearly indicate in the offer various costs under the No comments No comments No comments NO comments NO comments No comments No comments No comments NO Comments No Comments.
6 following heads for commercial evaluation of the tender:
Unit Cost of the On Board Rolling Stock Condition Monitoring System for each coach, wagon and locomotive - including installation No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
(i) & commissioning.
Cost of the recommended spares and consumables required per annum during warranty period of three years and post-warranty period of No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
(ii) seven years thereafter.
Annual operational (day to day) and maintenance cost (AMOC) of the On Board Rolling Stock Condition Monitoring Systems and No comments No comments No comments NO comments NO comments No comments No comments No comments SKF,Suggest here NO Comments No Comments.
Ground Support Facilities respectively during warranty and post warranty period. to have a
discussion on the
warranty and
AMOC contect after
the technical
feasibility of the
product has ben
scrutinized by the
(iii) indian railways
depanding upon the
finalization of the
technology to be
adopted.

Any Must-change items to keep the system running and the periodicity of changing such must-change items, if any. No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
(iv)

The respondents must specify the Up-time of their system. Any non-availability of their system, below their specified Up-time shall incur No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
(v) penalty. Quantum of penalty shall be advised at the time of framing the final specifications.

7 QUANTITY VARIATION CLAUSE:


On calling the Bids and at the stage of placing Purchase Order, the purchaser reserves the right to vary the supply quantity by 30% after No comments No comments No comments NO comments NO comments No comments No comments No comments Noted. NO Comments No Comments.
the placement of the order but during the currency of the contract.
8 INSPECTION :
Inspection: Inspection will be carried out by Ministry of Railways or its nominated representative but the ultimate responsibility of the No comments No comments No comments NO comments NO comments No comments No comments No comments Noted and NO Comments No Comments.
compliance with various statutory and demanded clauses shall lie with the supplier. confirmed

QAP as per standard format must be submitted by the respondent for the equipment that they intend to offer for sale to Indian Railways No comments Complies(QAP No comments NO comments NO comments No comments No comments No comments Noted and NO Comments No Comments.
giving all relevant details of inspection procedures, reference standards, sampling plan, testing regime, etc. available as confirmed
Appendix-7)
9 WARRANTY:
The respondent will provide warranty at the nominated depot for 39 months from the date of supply or 36 months from date of No comments No comments No comments NO comments NO comments No comments No comments No comments SKF,Suggest here NO Comments No Comments.
commissioning, whichever is earlier. During warranty, the respondents shall rectify the defects, if any, in the On Board Rolling Stock to have a
Condition Monitoring System system by replacing components as necessary at his cost. Warranty is 3 years and post warrant is 7 discussion on the
years thereafter. warranty and
9.1 AMOC contect after
the technical
feasibility of the
product has ben
scrutinized by the
indian railways
If the warranty support is not provided within 15 (fifteen) days of notice demanding the same, Indian Railways shall levy appropriate No comments No comments No comments NO comments NO comments No comments No comments No comments depanding upon the NO Comments No Comments.
penalties for non-functioning of the system. For this purpose, even if a sub-assembly within a complete unit (one coach/wagon/locomotive) finalization of the
is not working, the entire coach, wagon or locomotive system shall be deemed to be non-functional. Rate of penalty shall be calculated and technology to be
notified at the time of calling for Request for Proposals. The rate of penalty shall be telescopic in nature so as to discourage non- adopted.
9.2 compliance for long duration.

Respondent shall also undertake to ensure availability of all requisite spare parts for a minimum period of 15 years after purchase from the No comments No comments No comments NO comments NO comments No comments No comments No comments Noted and NO Comments No Comments.
10 date of Letter of Acceptance of the offer when Technical and Commercial Bids are called for. confirmed

The respondent shall give an undertaking that should there be any need for modification arising out of field trials or during the currency of No comments No comments No comments NO comments NO comments No comments No comments No comments Noted and NO Comments No Comments.
11 the contract as per the deliverable functional capability promised by the respondent, it will be carried out by the respondent without any confirmed
cost to the Indian Railways.
12 PERFORMANCE GUARANTEE BONDS AFTER REQUEST FOR PROPOSALS ARE CALLED FOR
Contractor will have to give a Performance Guarantee Bond equivalent to 10% of the cost of the contract. No comments No comments NO comments NO comments NO comments No comments No comments No comments Noted and NO Comments No Comments.
(a) confirmed
Contractor will also have to give a Performance Guarantee Bond equivalent to 10% of the cost of AMOC at the time of entering into to No comments No comments NO comments NO comments NO comments No comments No comments No comments Noted and NO Comments No Comments.
(b) AMOC. confirmed
13 SUBMISSION OF OFFERS WHEN BIDS ARE CALLED:-
When the Bids are called for, the Bid offers shall be submitted in triplicate, as two-packet system offers. The offers should be addressed to No comments No comments NO comments NO comments NO comments No comments No comments No comments Noted NO Comments No Comments.
and submitted to:
Executive Director Mechanical Engineering (Development), Room No. 333,
Rail Bhavan, Raisina Road
Ministry of Railways, New Delhi - 110001. India
The name and address of the Respondents should clearly appear on all the envelopes.
14 VALIDITY OF RESPONSE TO THE EXPRESSION OF INTEREST
The respondents must keep their response valid for consideration and for acceptance for a minimum period of 180 days from the last date No comments Complies(Valied No Coments Complies NO comments No comments No comments No comments Noted and NO Comments No Comments.
of submission of their comments as mentioned on Page 1 of this document. till 07.04.2016) confirmed

The authorized representative of the firm submitting the document must sign each page of the respondents document. In absence of the Document is in PDF Document is in Complies Complies NO comments No comments Complies No comments Noted and NO Comments The documents of specifications are signed by the firm. All other papers are unsigned by the authoritis.
signature, Indian Railways may assume that the firm has not authorized the response on such a page and such a response format signature PDF formet confirmed
page/document is liable to be disregarded or not taken cognizance of. available only on signature
2nd page available only on
1st page

15 LAST DATE OF RECEIPT & OPENING OF EXPRESSION OF INTEREST (EoI)


The response to EoI should reach the Executive Director Mechanical Engineering (Development), Ministry of Railways, Railway Board, EOI received on EOI received on EOI Recd. On EOI Recd. On EOI Received on 23/09/2015 by No comments EOI Recd. On 28.9.15 to EOI Recd. On Noted NO Comments Recd. On 7.10.15 to PS/EDME(Dev).
Room No.333, Rail Bhavan, Raisina Road, New Delhi 110001 not later than 14.30 hrs on 7 September 2015. The offers w ill be opened 28/9/15 06/10/15 7.10.15 to 7.10.15 to PS/EDME PS/EDME(Dev). 5.10.15 to
on the same date at 15:00 hrs. in the presence of respondents representatives who may like to be present in the tender opening. If in case PS/EDME(Dev). PS/EDME(Dev). PS/EDME(Dev).
the date of offer opening falls on a gazetted holiday or is subsequently declared as such, the offers will be opened on the next working date
at the appointed time as per above procedure.

16 THE REPONDENTS WILL BE SUBJECT TO:


Other General Conditions and stipulations contained in the bid documents followed by Indian Railways when the Bids for purchase of the No comments No comments No comments No comments NO comments No comments No comments No comments Noted NO Comments by firms No Comments.
(a) equipment are called for.
If and when sales tax on order (if placed) becomes payable under law, such payments when made will not be on contractors account. The No comments No comments No comments No comments NO comments No comments No comments No comments Noted NO Comments by firms No Comments.
(b) Ministry of Railways (Railway Board) will not, however, be responsible for the payment of sales tax paid by the contractor under
misapprehension of law.
Firms may indicate the rate at which they are capable of supplying the equipment to Indian Railways. If the progress of manufacture and No comments No comments No comments No comments NO comments No comments No comments No comments Noted NO Comments by firms No Comments.
supply or performance of the material and/or stores during inspection and tests is not considered satisfactory, the Purchaser may at his
(c) option and without any claim for compensation by the contractor, either cancel the order altogether or modify the quantity ordered.

The user interface for using the On Board Rolling Stock Condition Monitoring System should be developed by the supplier to the No comments No comments No comments No comments NO comments No comments No comments No comments Noted NO Comments by firms No Comments.
satisfaction of Indian Railways. The supplier shall do necessary customization in the front-end interface as per the requirements of Indian
17 Railways at the cost of supplier. This exercise shall be done to mutually acceptable demands from users.
Structural
IRD Mechanalysis
Requirements Amsted Rail(IONX) Medha Apna Tech. Stone India Solutions RSL Electronics Spec. Star Navigation SKF Secure rail Perpetuum RT Vision
Ltd.
Private Ltd.
A. Key Objectives
The On Board Condition Monitoring System of Rolling Stock will enable
Predictive Maintenance of coaches, wagons, locomotives and track by
meeting the following functionalities:
a. Improving safety by early warning of distress in or impending failures in IONX Partialy Complies. IONX Noted Complies No comments Scalable to No comments. Complies No comments SKF has the capability to monitor all the mentioned No comments. 1.Track condition monitor need much more details than just
wheels and wheel bearings. Using the vibration signature of the same consideres the monitoring of track Temperature sensing parameters in the functionality requirements of on vibration data.It needs Gyro sensors and its data analysis in real
sensors that are strategically placed on unsprung mass to do track condition to be related to impact monitoring on Bogies, Wheels board condition monitoring but the system time.Recent Twin almost Simultaneous accident in South india
monitoring too to indicate deterioration in the health of tracks thereby avoiding with accelerometers not vibration Brakes and Axels ,and requirements are slightly different to have accurate was due to sinking tracks during this monsoon.Trains have
sudden failures in service. The system must have scalability to monitor monitoring with accelerometers. track monitoring and authentic data, it is advisable to have separate passed such area as early as 30 minutes before accident. They
traction equipment, bogie frame structural health, brake cylinder pressure, IONX does not currently have provided is mentioned. system for auxiliary, track and other monitoring as it detected no abnormality. Furthermore such tracks never sink
brake cylinder stroke and coach interior parameters, like temperature, battery monitoring for coach battery health, Low power has different vibration algorithms and frequencies. suddenly. Another cause could be tilting tracks on any side. 2.
health, battery charging systems and air conditioning systems etc. battery charging systems and air consumption system is Twin simultaneous Accident was only due to absence of any type
conditioning systems however the used so Battery of communication between Drivers or Guards BETWEEN Trains.
IONX edge devices and platform maintenance is Our proposed system of Train Wireless network,using Wi-Fi or
have been designed to readly eliminated. Zigbee will ensure Inter Train communication. (3)Every passing
accomodate in future. ) trains,weather Passenger or Goods or Inspection vehicles or sole
engines or locomotives Must forcefully handshake communicate
with structured data sets. Data security levels and data structures
and other parameters will be dynamic and periodically updated
from cloud. (4)In case of failure of data communication with
Cloud, still data connection and handshake must be carried out
with default setting for each trains. (5)Compulsory handshake will
not be limited to between passing trains alone. This will also be
done compulsorily with stations, Level crossings
(Manned/unmanned) Loco/Car sheds and others. (6)Trains must
be equipped with weather sensors for weather data which could
affect railway operations and its safety. (7)These data will also be
useful to Indian met department through the Cloud. As it is not
possible to get Met data all over India, particularly in hostile and
unhabitated areas (8)Hooters at unmanned Level crossings.

b. Improvement in reliability of these assets by detecting early signs of IONX Complies. Noted Complies No comments Track condition No comments. Complies No comments Noted Complies. (1)Any deterioration in wheels
deterioration in wheels, wheel bearings and track condition. Monitoring is cracks,Alignment,Bearings,Suspension etc will always reflect in its
mentioned . frequency analysis. Also it is necessary to CORRELATE such
frequency analysis between wagons/bogies in same train. This is
just to isolate defects in a particular wagon or defect in track. The
track defect will show high correlation index.( 2)If Frequency
signature is similar between wagons but abnormal, then its track
defects. Else its wagon defect. (3)This type of Diagnostics will be
further supplemented by Cloud Analytics. As they are supposed to
be much more powerful engines with massive data handling
capacities with past historical archived data. (4)Local analysis of
frequency or Tilt signatures will invariably raise alarms at various
levels which can be tackled by local servers. Purpose of local
servers are for handling real Crisis or serious cases which are
obvious and clear.For all other cases Cloud based servers facility
will control operations. (5)It will be normal many times Cloud
server get disconnected from train.This could be due to
communication problem or any other.In such cases,local server
must do store Forward critical data,at a later stage of connectivity.
c. Enabling scientific decision-making for maintenance of assets IONX Complies. Amsted rail (AR) Noted No comments No comments No comments No comments. No comments. No comments Noted Complies. No comments
based on accurate deterioration trending and quantified indices of state ofthe parent company of IONX
health of these assets so as to plan condition-based maintenance rather than
manufactures
time-based maintenance. wheels,axles,bearing,bogies,and
cushioning equipment. AR uses
component health metrics
supported by IONX to drive
product design development,
product support and improve
product quality.
d. Reducing maintenance cost of the railway assets by (i) identifying IONX Complies Noted No comments No comments No comments No comments. Cost effective system architecture: Eliminates No comments Noted Complies. No comments
unnecessary maintenance regimes (ii) reduced replacement of still redundant hardware elements such as GPS,
serviceable components and (iii) more efficient deployment of maintenance GPRS modules. Significantly reduces fees for
resources. GPRS network service provider, by using
single point out-going communication.
e. Abilityto Install On Board Condition Monitoring System on Rolling Stock IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted Complies. No comments
on in service trains without having to take them down for major
modifications thereby reduced cost of installation, increased asset
availabilityand prevention of train service disruption while reaping benefits of
such predictive maintenance systems.
f. The proposed system should be capable of being used with existing IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted Complies. No comments
roller bearings and running systems on board the Indian Railways rolling
stock without having to make any structural modifications in the stock.
g. Easy operation of the On Board Rolling Stock Condition Monitoring IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted Complies. No comments
System by simple, automatically generated and actionable alerts.
h. Options to enhance the functionality and capability of this system in the IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted Complies. No comments
future without requiring major replacement of the existing equipment
monitoring system.
B. Key Requirements
1. Vendors Qualification:
The vendors must be ISO:9001 certified and should have proven experience IONX Complies Noted and Complied ISO Certified ISO9001:2008 ISO9001:2008 certified ISO9001:2008 certified , but No comments. No comments Complied. No comments. Complies
of delivering these systems in large volume to the rail industry. certified , but , but delevering delevering experience No
delevering experience No comments .
experience No comments .
comments .
Following experience shall be the minimum acceptable experience for the
respondents to qualify them for taking part in the bidding process when
request for proposal is called for:
a. Installation of at-least 5,000 wireless sensors on trains across different IONX Complies Noted and Complied (Medha has Working with Indian No comments No comments No comments. No comments. No comments SKF has wide experience in wired vibration sensor Complies. (1)This limits number of Vendors to a great extent.Furthermore,
types of Coaches or freight cars. These sensors must have run in the field for wide exposure in Rolling stock Railways for past 8 technology and analysis.SKF has the remot diagnostic such organisations may not give best possible solutions
at least 2 (two) years. equipment and almost 3200Alco Years. centres across the globe.SKF has completed considering safety aspects from a much bigger Macro level
locos, 650EMD locos and 1100 approximately 1 lakh sensors installations across the scenario or suitable to Indian operating conditions.(2)These days
Coach on-board equipments glob in all applications for Temperature,vibration and world is flooded with IOT based companies with much higher
with wide veriety of sensors and speed.As there is no differance in the installation of capabilities with data analytics,Software and Hybrid networking
different mission critical wired or wireless sensor, the only differance in the features.They might not have done such IOT for railways or any
application equipments are in mode of programming. In wired system data moving stocks.It is incomprehensible why such
operation in Indian concentrator is attached with the sensors through wire companies/vendors be excluded.(3)Another example is car
railways).Mostly used wired and programming is done in makers use such sensors with wireless for quite some time
sensors and wireless sensors concentrator.Concentrator will transmit data through now.Such car speeds often exceed that of Railway fastest train
are in development stage for cloud.This is exactly same as wireless system regularly similarily also major aircraft and its enging makers.(4)We
various applications. communication. request that this criteria shall not be applicable on Indian Firms or
Firms with technical persons who have filed patents/reports or
offers for similar application systems or capability to develop
similar systems on using Digital Signal Processing.(5)25 to 50%
business should be reserved for Indian Firms desirable to develop
system in India
b. Experience of over 1,000,000,000 sensor-kilometres of accumulated IONX complies. IONEX has used Noted and complied (Medha has No comments. No comments No comments No comments. No comments. No comments Complied. Complies. (1)We request that this criteria shall not be applicable on Indian
service operation of wireless (non-battery) sensor nodes. solar powered devices which more than one billion operational Firms or Firms with technical persons who have filed
upgraded to ultra low power Kilometers experience for rolling patents/reports or offers for similar application systems or
devices powered by long life stock on-board equipment and capability to develop similar systems on using Digital Signal
batteries.IONX has much success sensor technology Processing
with ultra low power systems and
has found no need to move away
using long life batteries for these
systems. However IONX is working
on an energy harvesting project
that will be deployed to extended
sensor life.

c. Demonstrate to Indian Railways how costs have been reduced with IONX Complies Noted and complied(Medha and No comments. No comments No comments No comments. No comments. No comments Noted and complied Complies. No comments
other customers using the system. its technology collaborators has
wide experience and ample of
expertise for rolling stock and
industrial expertise)
d. Names of at least three customers along with their contact details who IONX Complies Noted and complied (Will be Complies (1)ABB Ltd., No comments No comments No comments. No comments. No comments SJ Sweden,Metro Barceleno and Nomad Tech YES.We would need to include No comments
shall supply testimonials as asked for in (a), (b) and (c) above for the systems provided) Mumbai (4) Ashok network rail as 3rd customer but they
installed by the respondent. Leyland Ltd., Chennai would be a user of the information
(3) Bharat Electronics rather than a Purchaser of the
Ltd., Bangalore hardware
e. Ability to demonstrate successful detection of damaged bearings with IONX Complies. IONX Noted and complied (Medha and No comments No comments No comments No comments. Complies No comments Complied Complies. No comments
more than three months of the remaining service life of bearings on in-service recommends reporting its technology collaborators can
train. deteriorated bearing health in prove the ability to demonstrate)
Km.of service not month of
services
f. The effectiveness of the wheel and bearing condition monitoring system The primary focus of INOX is on Noted and complied No comments No comments No comments No comments. Complies No comments SKF has the capability to monitor all the mentioned NO. No freight No comments
shall be already proven in passenger coaching vehicle and freight service. monitoring freight wagon however parameters in the functionality requirements of on deployment/Howeverthe principle for
Examples of successful wheel and bearing monitoring case studies wherein its core methods can be applied to board condition monitoring but the system freight will be the same as for
damage to bearing, wheel and track was successfully demonstrated well passenger coaches or other requirements are slightly different to have accurate Passenger coaches.
before occurrence of failure must be furnished with photographs of damages assets in the Indian railway feet. and autherntic data,it is advisable to have separate
so detected, their laboratory test results and field staffs observations. Likely differences between freight system for auxiliary,track and other monitoring as it
wagon and coaches will be found has different vibration algorithms and frequencies.
in the installation of the devices
2. Deliverables expected from the System:
2.1. Systemshall be capable of operating effectively with 2G cellular data IONX Complies with 2G Noted and complied Complies No comments No comments No comments. Complies Complies Smart sensor is incorporated 2G and 3G capbilities. Complies. No comments
network coverage. System must be scalable to upgrade to 3G and 4G as and services.(IONX will comply with 3G
when needed in future without having to replace the complete data & 4G requirement.)
concentrator.
2.2. All data shall be captured and transmitted to a central server for IONX has found that to reduce Noted and complied Complies No comments Ensure comliance. No comments Complies No comments Complied,however SKF focus is to provied valid data Complies. (1)Cloud Analytics will be mainly to support real time Trains
inspection and analysis from the data concentrator. It should be possible to power consumption across its ta the customer, to avoid huge data streaming hance operations.This is due to limitations of Local train Control servers
decode and extract this data stream at the input to the analysis software for asset monitoring system so that reduces and cloud analytic support decisions will override any of Local
later use by Indian Railways for its own analysis. ultra low levels can be achived it is servers commands.This will also reduce occurrences of various
best to distribute the data collection levels of false alarms being raised and actioned locally. Only
and processing capabilities across during contact loss,local server will be autonomous in Decision
the entire system - that is the data Support.
concentrator, wireless sensor
nodes, gateways and servers, all of
which make up the IONX Edge
platform

2.3. Algorithm for Actionable alerts should be built into the on-board IONX Complies Noted and complied Complies No comments SMS alert is provided, No comments Complies No comments Suggest for discussion NO.The Algorithm will be off the train (1)On Board HUDs(Head Up Display)wiil feature both Graphic a
system in such a way that Text Alerts (SMS) should be inferred by the system Algorithm for in the cloud.Caculation wiil be done inwell as audio and text informations about not only Trains critical
on board itself. Such alerts should also be transmitted to on-board display, Actionable alert are the cloud and can then be relayed to features and Tracks but also environmental features,including
fixed or handheld device via appropriate wireless protocol without waiting for available, transmitting driver via the cellular network. weather.(2)Associated information must be local movement
GSM or CDMS network coverage. these alerts via pattern on GIS map as well as Rail Bridges,tunnels,Level
appropirate wireless crossings,culverts etc.(3)Since Drivers and Guards are not
protocol without GSM expected to be highly technical in nature this Display HMI must be
or CDMS is No designed with ease of use,understanding and apprehension and
comments. alarm.
2.4. Vibration data shall be captured at time intervals based on speed. If IONX partialy Complies. IONX Noted and complied No comments No comments No comments No comments Complies No comments Complied; the data will be stored inside the wireless NO.Time interval for data capture will No comments
required, it should be held in buffer on board the concentrator and then consideres the monitoring of track sensor.Note:-Measurent data /alert generation is not not be dependent on speed.They are
transmitted to a central database for processing, analysis and alert to be related to impact monitoring required to be done every 5 minutes for this condition. at fixed time intervals.The speed
generation every 5 minutes when the train is in normal service (at speeds with accelerometers not vibration threshold 25km/h rather than 15km/h
over 15 Km/h) and as soon as it comes into 2G cellular data coverage. In the monitoring with accelerometers.
event of cellular network not being available, the data shall be held for the IONX does not currently have
entire required time until cellular network coverage becomes available and monitoring for coach battery health,
then data must be transmitted at the earliest. The data holding buffer must be battery charging systems and air
designed accordingly. conditioning systems however the
IONX edge devices and platform
have been designed to readly
accomodate in future.
2.5. The condition monitoring system shall not be specific to any particular IONX sensors work with standard Noted and complied No comments No comments No comments No comments No comments. No comments Complied Complies. (1)Bearing is not the only cause of Railway safety other
bearing type or to any specific bearing supplier but should function with bearing E through GG. components like Brake parts,Wheels,Axle,Suspension springs
multiple types of bearings that are running on Indian Railways. and many parts may differ,So also different types of wagons,load
capacities,Open/closed/Platform types.Passenger bogies may
also be different types,different features and mechanical
characteristics.(2)Best solution would be for a dynamically
configurable sensor Box to cater to ALL type of
Wagon/Bogies/Loco etc.(3)Such Wagon etc will have dual set
RFID tags Implanted forever.Sensor Boxes will read such tags
and self-configure all parameters for each type.This will fully
ensure portability between various types of cars and locos used in
Indian Railway.(4)Of course Pre-Calibration of Sensors, based on
each type of Cars Transfer function, in both time and Frequency
Domain ,for different load and weather conditions, must be carried
2.6. Respondent must specify the accuracy of their system on overall basis IONX Complies Noted and complied No comments No comments No comments. No comments. No comments. No comments Noted and Complied YES.The system data accuracy will be No comments
with reference to FalsePositive and FalseNegative alarm performance. based on fied data from other
Methodology of verifying the stated accuracy including the test regime to be custoemrs rather than lab based test
followed to substantiate their claim must be specified. Indian Railways shall, regime.
while calling for technical and commercial bids, take into consideration these
details furnished by the vendors. In absence of any numbers given by the
respondents, Indian Railways shall set its own values based on its experience
of similar equipment running in the field in India.

2.7. The reliability of the system, or the acceptable failure rate of defect IONX Complies Noted and complied No comments. No comments No comments. No comments. No comments. No comments Noted and Complied NO. system lifetime to be specified 20 No comments
occurring within the system (hardware + Sensors + Software alerts), should years
be compliant to Six Sigma standard.
2.8. Vibration shall be measured and transmitted when train is operating in IONX Complies Noted and complied No comments No comments No comments. No comments. Complies No comments Noted and Complied NO.The speed threshold 25km/h (1)Though it will be useful to shut down sensors when train is in
normal service (speed greater than 15 Km/h) and shall continue to be rather than 15km/h static mode,at least Server sensors must be on .As servers will be
recorded for a minimum of 60 minutes after the train comes to a halt. on Battery or external power through Traction or otherwise.(2)It is
very common now to see accidents happening between static and
moving trains on same track.audio frequency level sensors may
detect a moving train on same track.(3)This is because a moving
train on a track will generate audio signals along tracks,without
much attenuation and at much higher speed than in air which may
2.9. The system shall be capable of measuring and transmitting an alert IONX Complies Noted and complied Complies No comments No comments. No comments. Complies Complies Noted and Complied diff comments
NO.the typicaly time 3 minute with No b id d l t
/email in the event of detecting a high risk occurrence within typically one amax. 7 minute
minute and maximum five minutes with appropriate 2G/3G/4G data
connectivity Time stamp of the system shall be used to verify this aspect
2.10. A data concentrator shall be used to collect information from all the IONX Complies Noted and complied Complies No comments No comments. No comments. Complies but monitoring datafrom at least four No comments System will have individual sensors each with their Complies. No comments
sensors fitted on the coach/wagon/locomotive. Each data concentrator shall vehicles not mentioned. own cellular communication capability.Sensor will talk
be capable of monitoring data from at least four vehicles two in its front and directly to Cloud.SKF Technology does not need any
two on its rear. data concentrator for monitoring data.
2.11. Data concentrator must have built in redundancy to ensure that the IONX may comply in that if the data Noted and complied No comments No comments No comments. No comments. No comments. No comments No comments. Complies. No comments
system does not blank-out. concentrator can not transmit data
because it is out of cell lower range
it will store the data until such time
it comes into range. In addition
redundancy can be increased
using multiple systems per wagon.

2.12. The system shall have proven capability of detecting bearing damage IONX Complies .IONX Noted and complied No comments No comments No comments. No comments. Complies No comments Noted and Complied Complies. No comments
three months before a bearing change is required, allowing ample time for recommends reporting
the activity to be planned in with other maintenance activities. deteriorated bearing health in KM
of service not month of service
2.13. The condition monitoring software algorithm should report the state of IONX Complies No comments No comments No comments No comments. No comments. Complies No comments Noted and Complied Complies. No comments
the health of the bearing, wheels and the track on discreet band zone
Green Zone for unconditionally safe to run, Yellow Zone - for beginning of
noticeable deterioration and Red Zone - for indication to pull out the asset
as soon as possible since it is reaching an impending failure stage.
2.14. The bearing condition scale shall, after appropriate configuration and IONX Complies Noted and complied Complies No comments No comments No comments. No comments. No comments Noted and Complied Complies. No comments
calibration, enable the operator to distinguish between bearings with none or
low level of damage and those that required increased attention and finally
those requiring replacement to allow continued reliable operation of the train
without a line-failure of the bearing
2.15. Besides the above mentioned Zone Bands, all parameters of the all IONX Complies in that it provides Noted and complied No comments No comments No comments No comments. No comments. No comments Noted and Complied Complies. No comments
assets should be possible to be plotted and trended over time/distance to health metrices at periodic intervals
identify the deterioration rate/trend. This should enable prioritisation of for all components rather than
maintenance activities, thus enabling reducing damage to track and storing raw data
maximising useful wheel life
2.16. The wheel condition monitoring system must be able to enable the IONX Complies Noted and complied Complies No comments No comments No comments. Complies No comments Noted and Complied No comments. No comments
operator to detect defects arising of Rolling contact fatigue like wheel shelling
wheel cracks, wheel flats and wheel disc cracks, etc.
2.17. Inthe event of sensor damage a warning shall be generated to enable IONX Complies Noted and complied Complies No comments No comments No comments. No comments. No comments Noted and Complied,SKF sensors have a self test Complies. No comments
safe replacement at the next inspection interval. facility,which will report a sensor malfunction, to allow
the safe repacement of the sensor at the next
inspection interval
2.18. Alert levels shall be configurable and set by the operator to enable IONX Complies in that it will Noted and complied No comments No comments Ensures Compliance. No comments. No comments. No comments Noted and Complied No comments. No comments
simple, actionable responses. However, the vendor shall take the collaborate with IR to identify the
responsibility of identifying the values and setting the limits and alarm values and setting for alarm
thresholds. A time period of two months shall be given to the supplier to thresholds. Since IONX is not an
understand the Indian Railways operations and maintenance scenario and expert on Indian Railway
practices for setting such thresholds. The supplier shall be obligated to assist operations it is willing to discuss
Indian Railways personnel in understanding the logics of the thresholds so the level of responsbility it will
set by him to the full satisfaction of the Indian Railways personnel. A assume in this process.
maximum period of six months from the date of installation on the last vehicle
th
of the 6800 unit shall be permitted to the supplier to do any fine-tuning of
their system algorithms.
2.19. A system of email alerts and acknowledgements shall be available to IONX Complies No comments No comments No comments Email Alert provided No comments. No comments. No comments Noted and Complied Complies. No comments
implement a two level response assurance system. ,but number of level No
comments .
2.20. The training materials and documentation for the system shall include IONX can provide training material Noted and complied No comments No comments No comments No comments. No comments. No comments Noted and Complied Complies. No comments
historical examples of bearing, wheel and track defects that have been in which historical examples can be
monitored successfully, with a correlation between monitored degradation, included based on the analysis of
action taken by operator and parameter levels on return to normal after Indian Railway data.IONX is not in
maintenance. the position to provide examples
based on customer-confidential
data.
2.21. All sensor data shall be time, date and location stamped. Data IONX Complies Noted and complied Complies but No No comments No comments No comments. Complies butexact accuracy not mentioned. No comments Noted and Complied Complies. No comments
location shall be typically accurate to 50m or better. Time stamp shall be comments on accuracy
taken from the GPS system. .
2.22. The allocation of sensor nodes to a data concentrator and train will IONX Complies Noted and complied Complies No comments No comments No comments. Complies. No comments System will have individual sensors each with their Complies. No comments
be easily configured either through the terminal input of the data concentrator own cellular communication capability.all the
using non-contact programming device (Bluetooth, NFC, Zigbee) or by programming and diagnosis of the system.
remote connection with the user website.
2.23. The only configuration required for sensor nodes shall be the sensor IONX Complies Noted and complied Complies No comments No comments. No comments. Complies. No comments To identify axle box or wheel, wheel set number and Complies. No comments
node serial number with railway coach/wagon/locomotive number. side need to indentified.For programming axle box or
wheel number will be required.
2.24. Only standard Industry Communication protocols and encryption IONX Complies Noted and complied No comments No comments No comments. No comments. Complies No comments Noted and Complied No comments. No comments
algorithms shall be used in the system from data concentrator to the cloud.
Decryption keys shall be provided wherever necessary. Proprietary
communication protocols or data formats/information interchange formats
used by the system when interfacing during system integration with other
sensors or while scaling up the deployment should be shared with Indian
Railways.
2.25. IR should also be able to extract the raw data in usable format and IONX does not complies Noted and complied No comments No comments Ensures compliance . No comments. Complies. No comments Noted and Complied No comments. No comments
communication protocols being used between sensor and data concentrator.

3. System Configuration:
3.1. The Rolling Stock and Track Condition Monitoring System shall have Noted Complies. No comments Partially complies. No comments. Complies. Only mentioned about Compliance subject to remarks against 3.5 below Complies.
the following elements: communication system
3.2. Sensor module (Sensor Node). IONX Complies Noted Complies. No comments Complies. Complies. Complies. No comments Noted and Complied Complies. No comments
3.3. Communications network. IONX Complies Noted Complies. No comments Complies. Complies. Complies. Complies. Noted and Complied Complies. No comments
3.4. Analysis Software. IONX Complies Noted Complies. No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
3.5. Information Display should be provided using web access, dedicated IONX Complies Noted No comments No comments Ensures compliance . No comments. No comments. No comments SKF hasd the capability to integrate the onboard hand No comments. No comments
computer tablets and handheld devices that may be carried by the operations held device with Onboard condition monitoring system
staff on board the train. Supplying four tablets/handheld devices for each train But this feature is not a standard requirement.There
shall be a part of the supply of the above equipment one set per 10,000 (ten will be finacial implication which SKF and Indian
thousand) sensors. Also, developing application for such handheld Raiway can decide on a later stage.
device/tablet and supplying it to Indian Railways free of cost shall be the
responsibility of the supplier.
3.6. All the equipment shall conform to EN50126 (Railway Applications - IONX complies with comparable Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
The Specification and Demonstration of Reliability, Availability,maintainability standards and will test to the EN
and Safety (RAMS)). standard
4. Sensor Node:
4.1. The sensor node shall include sensors for both temperature and IONX complies in that it has a Noted Sensor node enclosure No comments Vibration and Only Vibration Sensors are Complies No comments Noted and Complied Complies. No comments
vibration. A single sensor node shall be capable of monitoring condition data temperature sensor and alternately contains 3 axis temperature Sensing mentioned.
from the track, wheel and bearing when fitted to the axle bearing assembly. uses an accelerometer to measure accelerometer to are mavailable .Other is
impacts rather than a vibration measure on board and No comments
sensor track
vibration,temperature
sensor to measure
temperature of the axel
box.
4.2. Sensor node shall be contained in a single robust housing with no IONX Complies Noted Sensor node is made of No comments Ensures compliance. Housing is IP 65 ,IP 67 etc. The Sensor nodes are connected to IDC and No comments Noted and Complied Complies. No comments
external electrical wiring or connections (for sensors powering or custom made rugged ,standard , But Wiring or MPU via RS232/RS485/USB connector via
communication purposes). This is essential to eliminate damage to cables or enclosure and of IP68 connections details No short range wireless communication.
connectors and ensure fail-safe operation. grade to work in harsh comments.
and rugged enviroment.

4.3. The sensor node should be deployed close to the axle box assembly IONX Complies by mounting on the Noted Sensor node shall be No comments No comments No comments. Complies No comments SKF recommendation is to mount the sensor directly Complies. No comments
and on the unsprung mass. bearing adaptor mounted close to axel on the axle box using the bolts for the cover.Sensor
boxby the suitable should be placed close to loaded zone of
clamping on the bearing(within 10 to 2 O'Clock position)
unsprung mass
4.4. The vibration sensor shall meet the following specifications: Deviation mentioned at No comments No comments No comments Complies No comments. No comments.
4.4.4 and 4.4.19
4.4.1. 3-axis acceleration data. IONX Complies Noted Complies No comments Complies . No comments. 3-axes vibrations sensor. No comments SKF can offer a one-axis vibration sensor which is Complies. No comments
enough to detect the damages.
4.4.2. Lower limit of detection 0.025 g RMS IONX does not complies. IONX Noted No comments No comments No comments No comments. No comments. No comments Noted and Complied Complies. No comments
senstivity is +/- 0.05g. (IONX
recommends low level deduction
on RMS based events greater than
0 1 'g')
4.4.3. Sensitivity better than 0.025 g IONX does not complies. IONX Noted No comments No comments No comments No comments. Sensitivity +/-10mV/G. No comments Noted and Complied Complies. No comments
senstivity is +/- 0.050 g. (IONX
recommends low level deduction
on RMS based events greater than
0 1 'g')
4.4.4. Sensor Bandwidth of at least 500Hz IONX Complies Noted Sensor node shall No comments upto 10KHz is 2 hz to 10KHz is mentioned . No comments. No comments Complied Complies. No comments
communicate on 2.4 mentioned .
GHz frequency for
instrumentation and
monitoring purposes
4.4.5. Sampling Data rate of at least 1000Hz IONX Complies Noted Complies No comments Continuous (32 hz to No comments. Sampling frequency: 1000Hz No comments It is not enough .Fourier transform is limited up to a Complies. No comments
512 Hz) & Burst max. frequency of approx 400Hz.
sampling (32 Hz to
10KHz ) mentioned .
4.4.6. Accelerometer measurement range of at least 16g IONX Complies Noted No comments No comments Ensures compliance. complies . Vibration range +/- 100G. No comments Noted and Complied Complies. No comments
4.4.7. Minimum available accelerometer range of 25g IONX Complies Noted Complies No comments No comments Complies . No comments. No comments Noted and Complied NO ,Max.available accelerometer No comments
range of 25g
4.4.8. Minimum survivable shock of 10000g (accelerometer only). IONX Complies Noted Complies No comments No comments Not Complies. Minimum survivable shock of 10000g. No comments Noted and Complied Complies. No comments
4.4.9. Typical train speed before measurements commence: 10 km/h based IONX Complies Noted No comments No comments No comments No comments. No comments. No comments Noted and Complied NO, train speed should be 25 km/h (1)Sensors should be able to measure speed themselves.GPS
on GPS. may be only limited to given location at the time T of an
alarm.(2)As in about to more,static train GPS man not work as in
forests hills tunnels Bridges etc or in even covered platforms
4.4.10. Exception alert time lag: typically three minutes subject to a IONX Complies Noted No comments No comments No comments No comments. Complies. Complies If there will be any high risk event or alert occurrence NO.the typicaly time 3 minute with No comments
maximum of five minutes with appropriate 2G/3G/4G data connectivity. For event detected,then this will priorirtized and alert will amax. 7 minute
sending such alerts to on-board handheld devices, the lag shall not be more sent through cellular network.
than 3 minutes.
4.4.11. Typical vibration reporting interval: 3 minutes IONX Complies Noted No comments No comments No comments No comments. No comments. No comments SKF not define of time interval Complies. No comments
4.4.12. Maximum vibration reporting interval: 15 minutes IONX Complies Noted No comments No comments No comments No comments. No comments. No comments SKF not define of time interval Complies. No comments
4.4.13. Vibration test levels (up to 500Hz): IONX Complies Noted No comments No comments No comments No comments. No comments. No comments No comments. Complies. No comments
4.4.13.1. The sensor will be capable of withstanding: No comments No comments. Complies. No comments
4.4.13.1.1. 7 hours at 17g RMS IONX test to AAR S5702 standard Noted No comments No comments No comments No comments. No comments. No comments It seems that the requirment is different than EN Complies. No comments
and will test to this specific 61373.In some parts much more stringent and in order
reqirements less.To be able to really understand much more
information is needed like test procedures etc
4.4.13.1.2. 6 minutes intermittent at 44g RMS IONX test to AAR S5702 standard Noted No comments No comments No comments No comments. No comments. No comments It seems that the requirment is different than EN Complies. No comments
and will test to this specific 61373.In some parts much more stringent and in order
reqirements less.To be able to really understand much more
information is needed like test procedures etc
4.4.13.1.3. 6 shocks in each axis at 4m/s or 600g x 1ms half sine. IONX test to AAR S5702 standard Noted No comments No comments No comments No comments. No comments. No comments It seems that the requirment is different than EN Complies. No comments
and will test to this specific 61373.In some parts much more stringent and in order
reqirements less.To be able to really understand much more
4.4.14. Sensor node shall comply with BS 7608:2014 (fatigue) and EN IONX test to AAR S5702 standard Noted No comments No comments No comments No comments. Complies. No comments i f
Noted ti Complied
and i d d lik t t d t Complies. No comments
13749:2011 (structures) assuming 75g fatigue and 105g proof loads for the and will test to this specific
sensor and fixing to the axle housing assembly. reqirements
4.4.15. Each sensor node shall have a unique electronic identification IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
number, accessible from the web/NFC reader and visible on the sensor label.

4.4..16. Sensor node shall be common to all axle bearing assembly IONX Complies Noted No comments No comments No comments No comments. The sensor nodes are installed on each axle No comments SKF sensor comes with integrated bracket.Signal path Complies. No comments
types. Customisation may only be required for the fixing bracket arrangement box of the bogies. for axle to sensor is very important to capture high
frequency signals.It provides early detections
4.4.17. Sensor node shall be sealed to IP68 standard. IONX Complies Noted Complies No comments Not Complies. ( IP 67 is Not Complies. ( IP 65 & IP 67 Complies. No comments Noted and Complied Complies. No comments
mentioned ) are mentioned )
4.4.18. Sensor node housing shall be surface treated to protect against IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
corrosion.
4.4.19. The bogie mounted sensor nodes mounted on the trains shall IONX Complies Noted Operating No comments complies . complies . Operating temperatures: -10 C to +125 C. No comments Noted and Complied Complies. No comments
o o
operate satisfactorily over the range of -10 C to +85 C. temperatures: -40 C to
+85 C.
4.4.20. Sensor node shall either communicate on an unlicensed IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
frequency for instrumentation and monitoring purposes or on a frequency
licensed by Indian Railways for the purpose.
4.4.21. No change of battery/power source shall be permitted in the IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted.SKF have chosen to use a battery powered Complies. No comments
sensor node during the service life of the sensor node in order to comply with system.Batteries are compact easy to install and easy
EN50126 (Railway Applications - The Specification and Demonstration of to maintain.No moving parts and lower cost compard
Reliability, Availability, maintainability and Safety (RAMS)). to power harvester.Power harvester needs the
5. On Train Communications Hub (or Data Concentrator):
5.1. The Data Concentrator shall incorporate a GPS location device. IONX Complies Noted Complies No comments Ensures Compliance . No comments. GPS is not required on each and every IDC Complies No comments. Complies.
since the GPS information will be provided by
the MPU.
5.2. A single data concentrator shall be capable of receiving sensor data IONX complies in situation when Noted Complies No comments No comments No comments. Complies No comments No comments. Complies. No comments
from at least two adjacent rail vehicles and transmitting it onwards for remote wagons are permanently coupled
processing and presentation.
5.3. Thedata concentrator shall be powered by Industry Standard 24V or IONX Complies with battery Noted Complies No comments No comments No comments. Complies No comments No comments. Complies. No comments
110V DC on-board power supply with a maximum current capacity of 1 Amp operation (IONX is developing a
at 110VDC. The power supply shall comply with EN50155 and RIA12. product with external power
capabilities)
5.4. The data concentrator shall have a battery power option, either IONX Complies with battery Noted Complies No comments Battery power option No comments. Complies No comments No comments. NO ,We canot charge the data No commens
for backup or as a main source of power along with energy harvester for operation (IONX is developing a with energy harvesting concentrator with an energy harvester
recharging the battery. In case the Data concentrator has to work on Battery product with external power faclility is available vibration levels will be too low as the
Back up, then the battery should be Compliant to UL Specifications and capabilities) ,other specification not DC will be loceted above the
should provide 72 Hours of backup functionality which shall be demonstrated mentioned. suspension.
by method as per RAMS standard. In case the data concentrator has to work
on the battery only, as in case of freight vehicles, the life of the battery with full
functionality of the system should be minimum 5 (FIVE) years.
5.5 The data concentrator shall have one RS232/RS485 and one USB ports IONX complies in that the device is Noted No comments No comments RS 232 with USB port No comments. Complies Complies No comments. NO,We have no current plan for USB No comments
for the following functions: designed to wirelessly transmit available . Port on the DC -We usally USB to
information so the ports are serial adapter to go from the PC -is
internal to the data concentrator. In this acceptable?
future models the ports can be
made external if this is important to
Indian Railway
5.5.1 Configuration using a simple serial ASCII terminal. IONX complies in that the device is Noted No comments No comments No comments No comments. No comments. No comments No comments. Complies. No comments
designed to wirelessly transmit
information so the ports are
internal to the data concentrator. In
future models the ports can be
made external if this is important to
Indian Railway
5.5.2 Continuous data streaming output that is compatible with alternative IONX complies in that the device is Noted No comments No comments Ensures compliance . No comments. Complies No comments No comments. Complies. No comments
means of communication. designed to wirelessly transmit
information so the ports are
internal to the data concentrator. In
future models the ports can be
made external if this is important to
Indian Railway
5.5.3. Taking backup of stored data or for reprogramming the data IONX complies in that the device is Noted No comments No comments Ensures Compliance . No comments. No comments. No comments No comments. No comments. No comments
concentrator. designed to wirelessly transmit
information so the ports are
internal to the data concentrator. In
future models the ports can be
made external if this is important to
Indian Railway
5.5.4. Data Concentrator should accept industry standard protocols like IONX complies in that the device is Noted Complies No comments Industry standard No comments. Complies No comments No comments. Complies. No comments
MODBUS. This will be used for reading the sensor data from third-party designed to wirelessly transmit protocol not mentioned
devices whenever they are fitted on the existing system. Data concentrator information so the ports are .
should be able to configure and transmit the field data from such devices. internal to the data concentrator. In
future models the ports can be
made external if this is important to
Indian Railway
5.6. The data concentrator shall be compatible with dual SIM cellular IONX does not complies because Noted This unit has 2G/3G/4G No comments No comments No comments. Complies No comments No comments. Complies. No comments
technology compliant with 2G, 3G and 4G protocols without need to IONX has found that dual SIMs are enabled SIM card to
change/replace internal circuit boards. not needed for roaming purposes connect the data
concentrator to OBCMS
central server. This
allow data concentrator
to transfer data to
server and to receive
configuration
commands from the
5.10. The data concentrator shall have low power status indicator IONX does not complies because Noted No comments No comments No comments. Complies No comments All the indication are available in smart sensor Complies. No comments
LEDs for: IONX recommends using a digital
record of these conditions
5.10.1. Power indicator. IONX does not complies because Noted Complies No comments No comments No comments. Complies No comments Compiled, smart sensor Complies. No comments
IONX recommends using a digital
record of these conditions
5.10.2. Battery status. IONX does not complies because Noted Complies No comments No comments No comments. Complies No comments Compiled, smart sensor Complies. No comments
IONX recommends using a digital
record of these conditions
5.10.3. Activity (Awake/Asleep). IONX does not complies because Noted Complies No comments No comments No comments. Complies No comments Compiled, smart sensor Complies. No comments
IONX recommends using a digital
record of these conditions
5.10.4. GSM/GPRS connection. IONX does not complies because Noted Complies No comments No comments No comments. Eliminates redundant hardware elements such No comments Compiled, smart sensor Complies. No comments
IONX recommends using a digital as GPS, GPRS modules.
record of these conditions
5.10.5. GPS position. IONX does not complies because Noted Complies No comments No comments No comments. GPS is not required on each and every IDC No comments Compiled, smart sensor Complies. No comments
IONX recommends using a digital since the GPS information will be provided by
record of these conditions the MPU.
5.10.6. Communications with wheel sensor nodes. IONX does not complies because Noted No comments No comments No comments No comments. Complies. No comments Compiled, smart sensor Complies. No comments
IONX recommends using a digital
record of these conditions
5.10.7. Communication with mesh or other sensor nodes. IONX does not complies because Noted No comments No comments No comments No comments. Complies. No comments Not applicable,since our system is not meshing. Complies. No comments
IONX recommends using a digital
record of these conditions
6. A set of indicators showing mobile data connection health and IONX Complies in that indicators Noted Complies No comments No comments No comments. Complies. No comments Standard GSM Phone modules do not provide Complies. No comments
signal strength at point of reception. are monitored electronically with a hardware health and signal strngth indicators. This
digital record for each device could be added if required,but it is not provide as
standard
i. The data concentrator shall have a single button that can be IONX Complies Noted No comments No comments No comments. No comments. Complies. No comments
used to prompt the following actions:
1. Connection to the local terminal. IONX Complies Noted No comments No comments No comments No comments. No comments No comments No comments. Complies. No comments
2. Data connection for status report. IONX Complies Noted No comments No comments No comments No comments. No comments No comments No comments. Complies. No comments
3. Test mode. IONX Complies Noted No comments No comments No comments No comments. No comments No comments No comments. Complies. No comments
ii. The data concentrator shall have an IP 67 rating. IONX Complies Noted IP68 rating compliance. No comments No comments No comments. Complies. No comments No comments. Complies. No comments
iii. The data transmitted from the data concentrator to the remote IONX Complies Noted No comments No comments No comments No comments. Complies. No comments No comments. Complies. No comments
storage and processing centre shall be encrypted to an applicable industry
standard.
iv. The SIM card for data communication to the remote server shall IONX Complies Noted No comments No comments No comments No comments. Complies. No comments No comments. Complies. No comments
be protected inside the data concentrator housing. Special tools shall be
required to open the data concentrator (for example, security screws).
v. Radio communication antennas for the data concentrator shall IONX Complies Noted No comments No comments No comments No comments. Complies. Complies SIM cards are inbuilt as a chip in the sensor. Complies. No comments
be fit within the space available agreed with Indian Railways in the Schedule
of Dimensions and preferably on the box type.
vi. The data concentrator shall have an accelerometer with a IONX Complies Noted No comments No comments No comments No comments. Accelerometer range not mentioned. No comments No comments. Complies. No comments
minimum range of 2g and a resolution of 16bits.
vii. The data concentrator accelerometer shall have sleep function IONX Complies Noted No comments No comments No comments No comments. Complies. No comments No comments. Complies. No comments
when the train is stationary and shall be programmed to wake up when the
train moves to save battery power.
viii. The data concentrator shall comply with EN 45545:2013 IONX test to AAR S5702 standards Noted No comments No comments No comments No comments. Complies. No comments No comments. Complies. No comments
(Railway applications. Fire protection on railway vehicles. Requirements for and will test to meet this EN
fire behaviour of materials and components) standard
7. Software and Algorithms:
i. The software shall analyse the received sensor data and IONX Complies Noted Complies No comments Ensures Complince . No comments. Complies. No comments Noted and Complied Complies. No comments
produce simple actionable alerts for maintenance staff.
ii. The algorithms shall be coded into the software so that alerts IONX Complies Noted Complies No comments Ensures Complince . No comments. Complies. No comments Noted and Complied Complies. No comments
and condition information are generated automatically without the need for
manual intervention.
iii. The output from the software algorithms shall be a simple Noted No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
numerical value to quantify the seriousness of any emerging problem
depicting
1. Normal Health of bearing or other equipment being monitored. IONX Complies Noted Complies No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
2. Beginning of deterioration but degradation does not warrant IONX Complies Noted Complies No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
intervention.
3. Deterioration in the health of bearing or other equipment being IONX Complies . IONX Noted Complies No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
monitored that requires intervention within three months. recommends reporting
deteriorated bearing health in KM
of service not months of service

4. Deterioration in the health of bearing or other equipment being IONX Complies Noted Complies No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
monitored that requires immediate pull out from service at the next available
attention point.
iv. Actionablealerts that require immediate intervention shall be transmitted IONX Complies Noted Complies No comments Ensures Complince . No comments. Complies. No comments SKF would suggest that alerts are the first sent ot the NO,Caculation wiil be done in the No comments
to the on-board device/handheld terminals from intelligent sensor based cloud and then processed and pass down to train cloud and can then be relayed to
hardware logics and thresholds. These shall, in turn be transmitted to central operators.otherwise the node would need to keep a driver via the cellular network
data servers as per methods and timing described elsewhere in this list of all the possible hanheld device terminals -
document. whichwould not be practicable in such large proposed
network systems
v. Network configuration and viewing should be possible to create IONX Complies Noted Complies No comments No comments No comments. Complies. No comments The SKF proposed system will use a remote App to NO,Caculation wiil be done in the No comments
wireless mesh network of all sensors and data concentrators on the vehicles allow viewing of all the networks and their cloud and can then be relayed to
on the train so that it is possible to communicate the status of vehicle raising sensors.The bearing conditional states can be easily driver via the cellular network
an alarm to be identified with all its connected coaches or wagons. Such indentified so that it is possible to communicate the
alarm should be possible to be relayed to the locomotive and also at the level status of vehicle raising an alarm to be identified with
of the Cloud monitor all its connected coaches or wagons
8. Rolling Stock Monitoring System Requirements:
i. The system shall be capable of monitoring the following: No comments
1. Condition of wheels e.g. wheel flats, etc. IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
2. Surface and Sub-surface wheel damage like cracks and shelling on A research programme in place for Noted No comments No comments No comments No comments. No comments. No comments Noted and Complied Complies. No comments
disc as well as on tread e.g. those caused due to Rolling Contact Fatigue wheel monitoring with preliminary
(RCF) algorithms based on field data

3. Conditionof wheel bearings e.g. race damage, cup faults, cone faults, IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
growlers, etc.
4. Excessive and/or unusual vibration pattern that indicates abnormal IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
running behaviour of the wheel.
ii. Thesystem shall identify the condition of each specific wheel and wheel A research programme in place for Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
bearing separately to enable the maintenance work to be accurately directed wheel monitoring with preliminary
to exactly problem area. algorithms based on field data

iii. Thesystem shall have proven capability of identifying degrading bearing IONX Complies . IONX Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
at least three months in advance of the need to replace the bearing. recommends reporting
deteriorated bearing health in KM
of service not month of service

9. Track Monitoring System Requirements


i. Thesystem shall be capable of monitoring the track condition not only for IONX Complies. (A research Noted No comments No comments No comments No comments. Complies. No comments SKF recommendation is to use dedicated sensors for Complies. No comments
the level of shock and vibration but also the change of these levels with time programme in place for track track monitoring.To do a reailable track monitoring
so as to identify the deterioration trend. monitoring with preliminary data has to be collected countinously or with long time
algorithms based on field data) samples.SKF propse to use a wire IMX-B system.

ii. Informationshall be presented in a map view with highlighted areas of IONX complies by providing Noted Complies No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
highest shock and vibration. information on shock and impact
measurement
iii. The map view of vibration shall be updated continuously (as data IONX complies by providing Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
arrives) so as to monitor the progression of track defects as they develop. information on shock and impact
measurement
iv. The resolution shall depend on the number of wheels monitored and the IONX Complies Noted No comments No comments No comments No comments. No comments. No comments If wired solution is chosen number of wheel is not so Complies. No comments
frequency of service but shall be capable of daily updates subject to train importaint but train pass frequency eqipped with track
passage frequency. monitoring.
v. Thesystem shall provide the capability of viewing the vibration data as a IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
function of time and as a function of distance so that the customer can see
where the damage is and how it is evolving with time.
vi. The system shall be capable of accurately identifying which of the two IONX Complies Noted No comments No comments No comments No comments. Complies. No comments This needs to be discussed and it is a very difficult Complies. No comments
rails on a given track has a problem. requirment to complywith Locos,Coaches,trains can
be turned around.GPS information is only giving
position and direction of travel
vii. The system shall be capable of determining the train orientation. IONX Complies Noted No comments No comments No comments No comments. Complies No comments This needs to be discussed and it is a very difficult Complies. No comments
requirment to complywith Locos,Coaches,trains can
be turned around.GPS information is only giving
position and direction of travel
viii. The track condition monitoring system must enable the track maintaine IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
to prioritise track maintenance and repair based on quantitative indicator(s).

10. Installation
i. Sensor node shall typically be installed in less than 30 minutes by one IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
skilled worker under normal conditions and the required special (proprietary)
tooling will be supplied to all depots and maintenance sheds/workshops of
the Indian Railways
ii. Sensor node shall be capable of being fitted to the existing in- IONX complies to fit sizes E Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
service axle bearing assemblies at any time in the lifecycle of the bearing. through GG bearing adapters and
can adapt to other bearing adapter
sizes as needed
iii. Sensor node shall be capable of being fitted to both legacy IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
and new rolling stock without the need for buying special bearings or special
bearing housings/parts.
i. Sensor node fitment shall not require any change to the IONX complies to fit standard size Noted No comments No comments No comments No comments. Complies No comments SKF solution is to be use one of the cover bolts to Complies. No comments
existing bearings. The sensor nodes fitment shall be non-intrusive i.e. no bearing adapters fasten sensor.The EXISTING BOLT HAS TO be
requirement to modify the bearing or the bearing cap/casing. replaced by a slightly longer bolt
ii. Sensor node for wheels and wheel bearings shall be mounte IONX complies to fit standard size Noted Complies No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
on the unsprung part of the bogie to ensure monitoring of accurate vibration bearing adapters
data with adequate sensitivity.
iii. Necessary anti-pilferage measures as per international IONX complies with tamper Noted No comments No comments No comments No comments. Complies No comments Normal installation bolt has a hex style mount Complies. No comments
norms shall be built into the installation so as to reduce the danger of theft or resistant fasteners head.However if required we could make use of a
vandalism. security style head bolt,e.g. torx or similar to prevent
pilferage
iv. No hardwiring shall be permitted for provision of power or IONX Complies with all wireless Noted Complies No comments Ensure Compliance . No comments. Complies No comments Noted and Complied Complies. No comments
communication links to the sensor node. communication and self contained
power systems
v. The bogie frame mounted sensor nodes for monitoring IONX Complies Noted No comments No comments Ensure Compliance . No comments. No comments No comments To do bogies mounitoring SKF proposed a separate Complies. No comments
unusual bogie frame vibrations, at a later date, shall be self-powered. system.
vi. Sensor node configuration shall be facilitated by a wireless IONX Complies Noted Complies No comments Ensure Compliance . No comments. Complies No comments SKF ,suggest here to have a discussion on this as the Complies. No comments
communication/NFC/Bluetooth on each sensor that can be read using a feasibility of the actionable alerts can be done as it
handheld reader and then downloaded directly to the system needs further investments for the firms .
vii. Configuration Diagnostics: A suitable display and log shall IONX complies with a digital Noted Complies No comments No comments No comments. Complies No comments SKF proposal would be not use a concentrator,but to Complies. No comments
be provided to clearly show the list and health of all sensor nodes attached to reporting and log of successful use SMART sensors with in-built 2G/3GCellular
each data concentrator. If any data concentrators are not shown as attached, configuration and asssociation capability.
the technician shall be able to remotely check the concentrator pairing. The
replacement of the sensor node shall be possible in typically less than 30
minutes
viii. Data concentrator should be designed as vandal proof to IONX complies with tamper Noted No comments No comments No comments No comments. Complies No comments No comments. Complies. No comments
international standards and should be mounted on freight cars in a position resistant fasteners
and using means so as to minimize possibility of theft.
11. Environmental Requirements:
i. Sensor node shall comply with IP68 specifications. IONX Complies Noted Complies No comments Not Complies , But IP Not Complies. Complies. No comments Noted and Complied Complies. No comments
67 Mentioned .
ii. Sensor node shall comply with the following test No comments No comments. No comments
specifications for resistance to vibration and shock (both as applied to
equipment bolted to the axle box):
1. GM/RT 2100 IONX tests to AAR S5702 standard Noted No comments No comments No comments No comments. No comments. No comments The SKF Sensor is not changing any structural parts Complies. No comments
and will test to this standard too of the rolling stock.The sensor is small and has no
influence on any structural designs on the rolling
stock
2. EN61373:2010 IONX tests to AAR S5702 standard Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
and will test to this standard too

iii. The data concentrator shall comply with the requirements of IONX tests to AAR S5702 standard Noted No comments No comments No comments No comments. Complies. GM/RT 2100 not mentioned. No comments OK,EN61373 Complies. No comments
GM/RT 2100 and EN61373:2010 as applied to equipment mounted above and will test to this standard too
secondary suspension.
iv. The sensor node and data concentrator shall both comply IONX tests to AAR S5702 standard Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
with the requirements of BS EN 50125-1:1999 (or the latest edition where and will test to this standard too
required).
12. Communications:
i. Communications to and from the sensor nodes shall be IONX Complies Noted No comments No comments Ensures Compliance. No comments. Complies. Complies. Complies. No comments
wireless
ii. 2G/3G/4G Cellular or satellite communications shall be used IONX complies. IONX uses 2G and Noted No comments No comments Ensures Compliance. No comments. Complies. Complies. Noted and Complied Complies. No comments
to send data to and from the train. satellite communication (IONX will
comply with 3G and 4G
requirements)
iii. Data compression and filtering will be part of the on train IONX Complies Noted No comments No comments No comments No comments. Complies. Complies. Noted and Complied Complies. No comments
systems so that communications can be achieved effectively with 2G/3G/4G
cellular data communications
iv. The wireless communication from the sensors shall be free IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
from interference by passenger communication systems such as Wi-Fi,
Bluetooth and cellular radio.
13. Front-end presentation:
i. A user website shall be provided to display the current status IONX Complies Noted Complies. No comments No comments No comments. Complies. Complies. Noted and Complied Complies. No comments
of all monitored rail assets.
ii. The user website shall be used to configure sensor nodes to IONX Complies Noted Complies. No comments No comments No comments. Complies. Complies. Noted and Complied Complies. No comments
monitored rail assets.
iii. Information about the monitored rail assets on the user IONX Complies Noted Complies No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
website shall be compatible of accessibility with common mobile devices
(iPhone, Android, Windows phone, tablets) as well as standard desktop
computers running a web browser
iv. Sensor information shall be available as simple coloured IONX Complies Noted Complies No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
status diagrams, tables of numerical values indicating alert, equipment health
and diagnostic information, and graphical display of historical condition
information allowing comparison of on all common Internet browsers,
including mobile platforms
v. The information for monitored rail assets with sensors shall No comments
include but not be limited to:
1. Location (shown on a map and available as a downloaded data IONX Complies Noted Complies No comments No comments No comments. Complies. Complies. Noted .All points are not define but SKF propose Complies. No comments
file). separate system for track condition monitoring.
2. Speed. IONX Complies Noted Complies No comments No comments No comments. Complies. Complies. Complies. No comments
3. Direction. IONX Complies Noted Complies No comments No comments No comments. Complies. No comments Complies. No comments
4. Health state (including state of the sensors and data IONX Complies Noted Complies No comments No comments No comments. Complies. No comments Complies. No comments
concentrator).
5. Condition as indicated by vibration (monitored axles must include IONX complies in that it has a Noted Complies No comments No comments No comments. Complies. No comments Complies. No comments
bearing, wheel and track condition as output options). temperature sensor and instead of
a vibration sensor it uses an
accelerometer to measure impacts.

Necessary APIs (Application Program Interface) with for this, along with IONX Complies Noted No comments No comments No comments No comments. No comments. No comments No comments No comments No comments
the mapping software, should be developed by the supplier of the system
including obtaining any authorization for use of Geo-mapping data and
software
vi. The website shall be hosted on a non-proprietary cloud IONX will work with Indian Railway Noted No comments No comments No comments No comments. No comments. No comments Noted and Complied Complies. No comments
computing system with scalability, and geographical resilience with adequate to meet this requirement
redundancy and with mirrored redundant servers at each geographical
location. The preferred platform for this purpose shall be the secure ones that
are hoisted by Internationallycertified platform like those by Microsoft, Hewlett-
Packard, etc. whose Security Audit Certificate would require to be submitted
with the Technical Bid to begin with. This shall be later shifted on to India-
based Cloud services of choice that shall be jointly decided between the
supplier and Indian Railways. Cost of shifting over to Cloud in India shall be
b
vii. b th Theli website
f th shall
i display
t the train sets with the correct Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
vehicles order displayed on a single or layered webpage.
viii. The website shall have a top-level summary page displaying IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
summary status of the fleet.
ix. The website shall have multi-level query menu as per the IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
demands of Organizational hierarchy relevant to that particular
administrative level of person logging in.
14. Access to Data and Alerts:
14.1. Condition Monitoring information shall be securely accessible on IONX Complies Noted Complies No comments Ensures Compliance. No comments. Complies No comments Noted and Complied Complies. No comments
computer, tablet or smartphone from anywhere with broadband internet
access
14.2. Access to the information shall be passcode protected to a IONX Complies Noted No comments No comments No comments No comments. Complies Complies Noted and Complied Complies. No comments
recognised industry standard and shall be of hierarchical in nature depending
on the administrative position/privilege of the accessing client
14.3. Email/SMS Text alerts shall be provided when problems arise (with IONX Complies Noted No comments No comments Ensures Compliance. No comments. No comments. Complies Noted and Complied Complies. No comments
an option to provide text alerts to cellular phones).
14.4. The software shall escalate the urgent alerts to successive end IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
users in the event of acknowledge of the alert not being confirmed by its first
intended recipient.
15. Safety in design of system:
15.1. Sensor node shall be Rolling stock mounted to ensure repeated and IONX Complies Noted No comments No comments Ensures Compliance. No comments. Complies. No comments SKF is highly knowledgeable with large experience in Complies. No comments
frequent monitoring so as to identify faults at the earliest opportunity, avoid the condition monitoring requirements for railway and
missed events and allow reliable trending of condition information. will define the most suitable measurments repeat rates
to ensure reliable trending
15.2. Vibration sensors shall be provided for with auto calibration and IONX complies with auto calibration Noted No comments No comments No comments No comments. Complies. No comments self test mode will confirm the sensor operation.no Complies. No comments
temperature and humidity variation compensation for added accuracy, and temperature (IONX will calibration over the sensors life will be
reliability and safety. develop a humidity sensor) required.Temperature and humidity testing will be
conducted to ensure measurements are still within the
desired accuracy level required
15.3. An escalation mechanism shall be provided to support alert Can be developed Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
acknowledgement and ensure response in the event of high level alerts.
15.4. An audit trail shall be available to monitor and record website activity IONX Complies Noted No comments No comments No comments No comments. Complies. No comments Noted and Complied Complies. No comments
as well as data concentrator logs.
15.5. System shall be capable of self-monitoring for faults at least once in IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied Complies. No comments
24 hours.
16. Scalability and universality of the Onboard Condition monitoring system:

16.1. Both Rolling stock and track related information shall be IONX Complies Noted No comments No comments No comments No comments. Complies. No comments No comments. Complies. No comments
monitored and transmitted from the same sensor node.
16.2. The data communications system shall be scalable to allow IONX Complies Noted No comments No comments Scalable but Addition of No comments. Complies. No comments Noted and Complied Complies. No comments
addition of sensor nodes in future. sensor nodes in future
not confirmed.
16.3. Data concentrator shall be modular and should be scalable to IONX Complies Noted No comments No comments No comments No comments. If the load measurement option for freight cars No comments SKF proposal would be not use a concentrator,but to Complies. No comments
accept connection of additional sensors. For the protocol to be used for will be required, then 2 wireless weight use SMART sensors with in-built 2G/3GCellular
communications of the Data concentrator, kindly refer to clause 5.5.4. Apart sensors will be installed on each bogie of the capability.Since the sensor at autonomous,scaling of
from the hardware connectivity, software handshaking with sensors must freight cars and will transmit their results to the the system can be done.Additional non bearing
also be ensured. IDCs. sensors may be possible in the future,as the system is
the expandable and scalable
16.4. Additional input device in wireless fashion to the data IONX Complies Noted No comments No comments Not Mentioned. No comments. Complies No comments Noted and Complied Complies. No comments
concentrator to add more sensors.
16.5. The system shall be applicable to both passenger and freight IONX Complies Noted Complies. No comments Only mentioned Bogies No comments. Complies. No comments Noted and Complied Complies. No comments
trains/operations. but not differentiated
for passengers and
Frieght Trains.

16.6. System shall be capable of being scaled-up in future, with simple IONX Complies Noted No comments No comments No comments No comments. Complies No comments Noted and Complied No comments. No comments
addition of sensors by connecting them to data concentrator, to monitor the
following parameters. The list of parameters is not exhaustive and is not
limited to only the ones mentioned in Annexure 1
ANNEXURE 1
The following performance parameters of the coach, locomotive and freight
car shall be required to be optionally measured and monitored from the point
of view of predictive maintenance in the same lines as the standard
parameters for which the main system has been developed by the firm. All
equipment (and sensor) standards that are being demanded in the main
system shall apply to the expanded functionality requirement systems too
1. Additional parameters to be monitored in Passenger Coach:
a) Water level monitoring in water tanks on board the coach. IONX partially complies. Monitoring No comments Data concentrators are No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
Monitoring of internal temperature of carriage shall be available. of internal air temperature is modular,scalable and
available (IONX can develop a provided with
water tank level monitoring MODBUS,ZigBee,Bluto
sensor ) oth,Analog
b) Air-spring pressure (where ever pneumatic suspension springs IONX has pressure sensor in No comments input,potential free No comments No comments No comments. No comments. No comments Noted and Complied Complies. No comments
are fitted). development that could work for digital input contacts to
this application interface with third party
c) Wheel slip and slide control system. IONX does not complies No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
devices and more
devices and more
d) Air brake system piston travel and Brake cylinder pressure. IONX complies by measuring No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
number of sensor
piston force rather than piston
nodes that would be
travel (IONX has pressure sensor
added to each vehicle
in development that will work for
at the later stage. the
this application)
e) Brake pipe and feed pipe pressure. IONX has pressure sensor in No comments new sensor nodes No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
development that will work for this added to measure the
application optional parameters as
f) Distributor Valve performance of the Air Brake system. IONX has a brake monitoring No comments mentioned in this table No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
system in development that will can be seamlessly to
work for this application plugged- in to
g) Automatic door closer system. IONX is open to reviewing with No comments communicate with No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
Indian Railway its requirement for exixting data
such a sensor Concentrators.
h) Additional wheel damage differentiation such as flange wear, out IONX has a wheel impact system in No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
of round, etc. development
i) In case of Diesel Engine driven Diesel Multiple Units (DMUs), the IONX Complies No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
health of Gearbox, traction motors and compressor(s).
2. Additional parameters to be monitored in Freight Car (Wagon):

a) Brake systems brake piston travel. IONX Complies by measure piston No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
force rather than piston travel

b) Brake cylinder pressure. IONX has pressure sensor in No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
development that will work for this
application
c) Brake pipe and feed pipe pressure. IONX has pressure sensor in No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
development that will work for this
application
d) Brake system Distributor Valve health functional or non- IONX has brake monitoring system No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
functional. in development that will work for
this application
e) State of wagon whether Empty or Loaded. IONX Complies No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
f) Additional wheel damage differentiation such as flange wear, out IONX has a wheel impact system in No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
of round, etc. development
g) Broken spring in the suspension system. IONX does not complies No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
h) Crack on bogie frame. IONX does not complies No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
3. Additional parameters to be monitored in Locomotive:
a) Brake systems brake piston travel. IONX Complies by measuring No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
piston force rather than piston
travel
b) Brake cylinder pressure. IONX has pressure sensor in No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
development that will work for this
application
c) Brake pipe and feed pipe pressure. IONX has pressure sensor in No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
development that will work for this
application
d) Brake system Distributor Valve health functional or non- IONX has brake monitoring system No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
functional. in development that will work for
this application
e) State of wagon whether Empty or Loaded. IONX Complies No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
f) Additional wheel damage differentiation such as flange wear, out IONX has a wheel impact system in No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not cuurently available No comments
of round, etc. development
g) Broken spring in the suspension system. IONX does not complies No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not currently available No comments
h) Crack on bogie frame. IONX does not complies No comments No comments No comments No comments. No comments. No comments Noted and Complied Pending ,not currently available No comments